Absorbent article with an exudate management layer

ABSTRACT

An absorbent article can have a topsheet layer, a liquid impermeable layer, and an absorbent core positioned between the topsheet layer and the liquid impermeable layer. The absorbent article can further include an exudate management layer in fluid communication with the topsheet layer. In various embodiments, the exudate management layer can be positioned on a body facing surface of the topsheet layer. In various embodiments, the exudate management layer can be positioned between the topsheet layer and the absorbent core. The exudate management layer has a first component which defines an opening for direct passage of body exudates into the absorbent core. The exudate management layer has a second component which at least partially overlaps the first component of the exudate management layer and further extends in the longitudinal direction of the absorbent article in a direction towards the posterior region of the absorbent article.

BACKGROUND OF THE DISCLOSURE

A primary function of a personal care absorbent article is to absorb andretain body exudates such as urine and fecal material with additionaldesired attributes including low leakage of the exudates from theabsorbent article and a dry feel to the wearer of the absorbent article.Currently, a wide variety of products for absorbent of body exudates areavailable in the form of diapers, training pants, and incontinencedevices. These products generally have an absorbent core positionedbetween a body-facing liquid permeable topsheet layer and agarment-facing liquid impermeable layer. The edges of the topsheet layerand the liquid impermeable layer are often bonded together at theirperiphery to form a seal to contain the absorbent core and body exudatesreceived into the product through the topsheet layer. In use, suchproducts may have a front waist and rear waist region which can encirclethe lower torso of the wearer to remain in place on the body of thewearer.

Absorbent articles commonly fail, however, to prevent leakage of bodyexudates. Some body exudates, such as solid and semi-solid fecalmaterial, have difficulty penetrating the topsheet layer of theabsorbent article as easily as urine and tend to spread across thesurface of the topsheet layer under the influence of gravity, motion,and pressure by the wearer of the absorbent article. The migration ofsuch body exudates is often towards the perimeter of the absorbentarticle, increasing the likelihood of leakage and smears against theskin of the wearer which can make clean-up of the skin difficult.

An additional problem is that such conventional absorbent articleproducts may not always have an adequate fit to the body of the wearerwhich can lead to increased levels of leakage of body exudates from theproduct and discomfort during wear of the product. Many conventionalabsorbent article products are flat or have flat regions prior to usewhile the wearer's body is contoured. Even though the flat absorbentarticle product can bend during use, it can still fail to fully conformto the body of the wearer which can result in gaps between the productand the skin of the wearer resulting in leakage of body exudates,particularly those body exudates, such as solid and semi-solid femalmaterial, which have a more difficult time penetrating the topsheetlayer of the product. The movement of the wearer can also causeundesirable deformation of the product and fold lines within the productwhich can create pathways along which the body exudates can travel andleak from the product.

There remains a need for an absorbent article that can adequately reducethe incidence of leakage of body exudates from the absorbent article.There remains a need for an absorbent article which can provide improvedhandling of body exudates. There remains a need for an absorbent articlethat can minimize the amount of body exudates in contact with thewearer's skin.

SUMMARY OF THE DISCLOSURE

In various embodiment, an absorbent article can have a longitudinaldirection and a transverse direction; a longitudinal centerline and atransverse centerline; an anterior region, a posterior region, and acentral region positioned between the anterior region and the posteriorregion; an anterior region transverse direction end edge, a posteriorregion transverse direction end edge, and a pair of longitudinaldirection side edges extending between and connecting the anteriorregion transverse direction end edge and the posterior region transversedirection end edge; a topsheet layer defining a body facing surface ofthe absorbent article, a liquid impermeable layer defining a garmentfacing surface of the absorbent article, and an absorbent corepositioned between the topsheet layer and the liquid impermeable layer;and an exudate management layer in fluid communication with the topsheetlayer; the exudate management layer comprising a first component atleast partially defining an opening in the exudate management layer; anda second component connected to the first component via a primary fold,the second component extending from the primary fold in the longitudinaldirection towards the posterior region of the absorbent article, whereinthe opening is positioned between the transverse centerline and theposterior region transverse direction end edge.

In various embodiments, the exudate management layer is positioned onthe body facing surface of the topsheet layer. In various embodiments,the exudate management layer is positioned between the topsheet layerand the absorbent core.

In various embodiments, the absorbent article further has an acquisitionlayer.

In various embodiments, the second component comprises a secondary fold.

In various embodiments, the absorbent article further has a thirdcomponent connected to the primary component of the exudate managementlayer via a third component primary fold. In various embodiments, thethird component extends from the third component primary fold in thelongitudinal direction towards the anterior region of the absorbentarticle.

In various embodiments, the second component at least partially overlapsthe first component. In various embodiments, the second component atleast partially underlaps the first component.

In various embodiments, the absorbent article further has an opposingpair of containment flaps extending in the longitudinal direction of theabsorbent article.

In various embodiments, the topsheet layer is a fluid entangled laminateweb comprising a support layer comprising a plurality of fibers andopposed first and second surfaces; a projection layer comprising aplurality of fibers and opposed inner and outer surfaces, the secondsurface of the support layer in contact with the inner surface of theprojection layer, fibers of at least one of the support layer and theprojection layer being fluid-entangled fibers of the other of thesupport layer and the projection layer; a plurality of hollowprojections formed form a first plurality of the plurality of fibers inthe projection layer, the plurality of hollow projections extending fromthe outer surface of the projection layer in a direction away from thesupport layer; and a land area, wherein the plurality of hollowprojections are surrounded by the land area.

In various embodiments, the absorbent core has a body facing surface andprojections extending away from the body facing surface of the absorbentcore.

In various embodiments, the second component comprises at least oneopening.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side view of an exemplary embodiment of an absorbentarticle.

FIG. 2 is a top down view of the absorbent article of FIG. 1 withportions cut away for clarity.

FIG. 3 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 4A is an exploded cross-sectional view of the absorbent article ofFIG. 3 taken along line 4A-4A.

FIG. 4B is an exploded cross-sectional view of the absorbent article ofFIG. 3 taken along line 4B-4B.

FIG. 5 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 6A is an exploded cross-sectional view of the absorbent article ofFIG. 5 taken along line 6A-6A.

FIG. 6B is an exploded cross-sectional view of the absorbent article ofFIG. 5 taken along line 6B-6B.

FIG. 7 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 8A is an exploded cross-sectional view of an exemplary embodimentof the absorbent article of FIG. 7 taken along line 8A-8A.

FIG. 8B is an exploded cross-sectional view of an exemplary embodimentof the absorbent article of FIG. 7 taken along line 8B-8B.

FIG. 9A is an exploded cross-sectional view of another exemplaryembodiment of the absorbent article of FIG. 7 taken along line 9A-9A.

FIG. 9B is an exploded cross-sectional view of another exemplaryembodiment of the absorbent article of FIG. 7 taken along line 9B-9B.

FIG. 10 is a perspective view of an exemplary embodiment of a topsheetlayer.

FIG. 11 is a cross-sectional view of the topsheet layer of FIG. 10 takenalong line 11-11.

FIG. 12 is a cross-sectional view of the topsheet layer of FIG. 10 takenalong line 11-11 showing possible directions of fiber movements withinthe topsheet layer due to a fluid entanglement process.

FIG. 13 is a photomicrograph of a cross-sectional view of a portion of afoam and fiber composite.

FIG. 14 is a photomicrograph of a planar view of the foam and fibercomposite of FIG. 13 such that the fibrous material is visible to theviewer.

FIG. 15 is a photomicrograph of a planar view of the foam and fibercomposite of FIG. 13 such that the second planar surface of the foammaterial and portions of fibers are visible to the viewer.

FIGS. 16A-16D are cross-sectional side views taken in the longitudinaldirection of exemplary embodiments of exudate management layers.

FIG. 17 is a perspective view of an exemplary embodiment of an exudatemanagement layer in fluid communication with an absorbent core.

FIG. 18 is a perspective view of an exemplary embodiment of an exudatemanagement layer in fluid communication with an absorbent core.

FIG. 19 is a top down view of an exemplary embodiment of an exudatemanagement layer.

FIG. 20 is a top down view of an exemplary embodiment of an exudatemanagement layer.

FIG. 21 is a top down view of an exemplary embodiment of an exudatemanagement layer.

FIG. 22 is a perspective view of an exemplary embodiment of an exudatemanagement layer.

FIG. 23 is a perspective view of an exemplary embodiment of an absorbentarticle.

FIG. 24 is a perspective view of an exemplary illustration of a set-upof an imaging system used for determining the percent open area of afluid entangled laminate web.

FIG. 25 is a perspective view of an exemplary illustration of a set-upof an imaging system for determining projection height of a fluidentangled laminate web.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the disclosure.

DETAILED DESCRIPTION OF THE DISLOSURE

The present disclosure is directed towards an absorbent article whichcan have an improved conformity to the body of the wearer of theabsorbent article providing for an improved intake and retention of bodyexudates such as fecal material. An absorbent article can have alongitudinal direction, a transverse direction, and a depth direction.The absorbent article can have an anterior region, a posterior region,and a central region. The absorbent article can have a topsheet layer, aliquid impermeable layer, and an absorbent core positioned between thetopsheet layer and the liquid impermeable layer. The absorbent articlecan further include an exudate management layer in fluid communicationwith the topsheet layer. In various embodiments, the exudate managementlayer can be positioned on a body facing surface of the topsheet layer.In various embodiments, the exudate management layer can be positionedbetween the topsheet layer and the absorbent core. The exudatemanagement layer has a first component which at least partially definesan opening for direct passage of body exudates into the absorbent core.The exudate management layer has a second component connected to thefirst component. The first component can provide the exudate managementlayer with a first height dimension and the second component can providethe exudate management layer with a second height dimension that isgreater than the first height dimension.

Definitions:

As used herein, the term “absorbent article” refers herein to an articlewhich may be placed against or in proximity to the body (i.e.,contiguous with the body) of the wearer to absorb and contain variousliquid, solid, and semi-solid exudates discharged from the body. Suchabsorbent articles, as described herein, are intended to be discardedafter a limited period of use instead of being laundered or otherwiserestored for reuse. It is to be understood that the present disclosureis applicable to various disposable absorbent articles, including, butnot limited to, diapers, training pants, youth pants, swim pants, andincontinence products, and the like without departing from the scope ofthe present disclosure.

As used herein, the term “airlaid” refers herein to a web manufacturedby an airlaying process In the airlaying process, bundles of smallfibers having typical lengths ranging from about 3 to about 52 mm areseparated and entrained in an air supply and then deposited onto aforming screen, usually with the assistance of a vacuum supply. Therandomly deposited fibers are then bonded to one another using, forexample, hot air to activate a binder component or a latex adhesive.Airlaying is taught in, for example, U.S. Pat. No. 4,640,810 to Laursen,et al., which is incorporated herein in its entirety by referencethereto for all purposes.

As used herein, the term “bonded” refers to the joining, adhering,connecting, attaching, or the like, of two elements. Two elements willbe considered bonded together when they are joined, adhered, connected,attached, or the like, directly to one another or indirectly to oneanother, such as when bonded to an intermediate element. The bonding canoccur via, for example, adhesive, pressure bonding, thermal bonding,ultrasonic bonding, stitching, suturing, and/or welding.

As used herein, the term “bonded carded web” refers herein to webs thatare made from staple fibers which are sent through a combing or cardingunit which separates or breaks apart and aligns the staple fibers in themachine direction to form a generally machine direction oriented fibrousnonwoven web. This material may be bonded together by methods that caninclude point bonding, through air bonding, ultrasonic bonding, adhesivebonding, etc.

As used herein, the term “coform” refers herein to composite materialscomprising a mixture or stabilized matrix of thermoplastic fibers and asecond non-thermoplastic material. As an example, coform materials maybe made by a process in which at least one meltblown die head isarranged near a chute through which other materials are added to the webwhile it is forming. Such other materials may include, but are notlimited to, fibrous organic materials such as woody or non-woody pulpsuch as cotton, rayon, recycled paper, pulp fluff, and alsosuperabsorbent particles, inorganic and/or organic absorbent materials,treated polymeric staple fibers and so forth. Some examples of suchcoform materials are disclosed in U.S. Pat. Nos. 4,100,324 to Anderson,et al., 4,818,464 to Lau, 5,284,703 to Everhart, et al., and 5,350,624to Georger, et al., each of which are incorporated herein in theirentirety by reference thereto for all purposes.

As used herein, the term “conjugate fibers” refers herein to fiberswhich have been formed from at least two polymer sources extruded fromseparate extruders and spun together to form on fiber. Conjugate fibersare also sometimes referred to as bicomponent or multicomponent fibers.The polymers are arranged in substantially constantly positioneddistinct zones across the cross-sections of the conjugate fibers andextend continuously along the length of the conjugate fibers. Theconfiguration of such a conjugate fiber may be, for example, asheath/core arrangement where one polymer is surrounded by another, ormay be a side-by-side arrangement, a pie arrangement, or an“islands-in-the-sea” arrangement. Conjugate fibers are taught by U.S.Pat. Nos. 5,108,820 to Kaneko, et al., 4,795,668 to Krueger, et al.,5,540,992 to Marcher, et al., 5,336,552 to Strack, et al., 5,425,987 toShawver, and 5,382,400 to Pike, et al., each being incorporated hereinin their entirety by reference thereto for all purposes. For twocomponent fibers, the polymers may be present in ratios of 75/25, 50/50,25/75 or any other desired ratio. Additionally, polymer additives suchas processing aids may be included in each zone.

As used herein, the term “machine direction” (MD) refers to the lengthof a fabric in the direction in which it is produced, as opposed to a“cross-machine direction” (CD) which refers to the width of a fabric ina direction generally perpendicular to the machine direction.

As used herein, the term “meltblown web” refers herein to a nonwoven webthat is formed by a process in which a molten thermoplastic material isextruded through a plurality of fine, usually circular, die capillariesas molten fibers into converging high velocity gas (e.g., air) streamsthat attenuate the fibers of molten thermoplastic material to reducetheir diameter, which may be to microfiber diameter. Thereafter, themeltblown fibers are carried by the high velocity gas stream and aredeposited on a collecting surface to form a web of randomly disbursedmeltblown fibers. Such a process is disclosed, for example, in U.S. Pat.No. 3,849,241 to Buten, et al., which is incorporated herein in itsentirety by reference thereto for all purposes. Generally speaking,meltblown fibers may be microfibers that are substantially continuous ordiscontinuous, generally smaller than 10 microns in diameter, andgenerally tacky when deposited onto a collecting surface.

As used herein, the term “nonwoven fabric” or “nonwoven web” refersherein to a web having a structure of individual fibers or threads whichare interlaid, but not in an identifiable manner as in a knitted fabric.Nonwoven fabrics or webs have been formed from many processes such as,for example, meltblowing processes, spunbonding processes, through-airbonded carded web (also known as BCW and TABCW) processes, etc. Thebasis weight of nonwoven webs may generally vary, such as, from about 5,10, or 20 gsm to about 120, 125, or 150 gsm.

As used herein, the term “spunbond web” refers herein to a webcontaining small diameter substantially continuous fibers. The fibersare formed by extruding a molten thermoplastic material from a pluralityof fine, usually circular, capillaries of a spinneret with the diameterof the extruded fibers then being rapidly reduced as by, for example,eductive drawing and/or other well-known spunbonding mechanisms. Theproduction of spunbond webs is described and illustrated, for example,in U.S. Pat. Nos. 4,340,563 to Appel, et al., 3,692,618 to Dorschner, etal., 3,802,817 to Matsuki, et al., 3,338,992 to Kinney, 3,341,394 toKinney, 3,502,763 to Hartman, 3,502,538 to Levy, 3,542,615 to Dobo, etal., and 5,382,400 to Pike, et al., which are each incorporated hereinin their entirety by reference thereto for all purposes. Spunbond fibersare generally not tacky when they are deposited onto a collectingsurface. Spunbond fibers may sometimes have diameters less than about 40microns, and often between about 5 to about 20 microns.

As used herein, the terms “superabsorbent polymer,” “superabsorbent,” or“SAP” shall be used interchangeably and shall refer to polymers that canabsorb and retain extremely large amounts of a liquid relative to theirown mass. Water absorbing polymers, which are classified as hydrogels,which can be cross-linked, absorb aqueous solutions through hydrogenbonding and other polar forces with water molecules. A SAP's ability toabsorb water is based in par on iconicity (a factor of the ionicconcentration of the aqueous solution), and the SAP functional polargroups that have an affinity for water. SAP are typically made from thepolymerization of acrylic acid blended with sodium hydroxide I thepresence of an initiator to form a poly-acrylic acid sodium salt(sometimes referred to as sodium polyacrylate). Other materials are alsoused to make a superabsorbent polymer, such as polyacrylamide copolymer,ethylene maleic anhydride copolymer, cross-linkedcarboxymethylcellulose, polyvinyl alcohol copolymers, cross-linkedpolyethylene oxide, and starch grafted copolymer of polyacrylonitrile.SAP may be present in absorbent articles in particle or fibrous form oras a coating or another material or fiber.

Absorbent Article:

The present disclosure is directed towards an absorbent article whichcan have an improved conformity to the body of the wearer of theabsorbent article providing for an improved intake and retention of bodyexudates such as fecal material. An absorbent article can have alongitudinal direction, a transverse direction, and a depth direction.The absorbent article can have an anterior region, a posterior region,and a central region. The absorbent article can have a topsheet layer, aliquid impermeable layer, and an absorbent core positioned between thetopsheet layer and the liquid impermeable layer. The absorbent articlecan further include an exudate management layer in fluid communicationwith the topsheet layer. In various embodiments, the exudate managementlayer can be positioned on a body facing surface of the topsheet layer.In various embodiments, the exudate management layer can be positionedbetween the topsheet layer and the absorbent core. The exudatemanagement layer has a first component which at least partially definesan opening for direct passage of body exudates into the absorbent core.The exudate management layer has a second component connected to thefirst component. The first component can provide the exudate managementlayer with a first height dimension and the second component can providethe exudate management layer with a second height dimension that isgreater than the first height dimension.

Referring to FIGS. 1, 2, 3, 4A, 4B, 5, 6A, 6B, 7, 8A, 8B, 9A, and 9B, anabsorbent article 10 of the present disclosure is exemplified in theform of a diaper. It is to be understood that the present disclosure issuitable for use with various other absorbent articles which aredesigned to be worn about the lower torso of a wearer, such as, but notlimited to, training pants or adult incontinence pants, withoutdeparting from the scope of the present disclosure. FIG. 1 is a sideview of an exemplary embodiment of the absorbent article 10 and FIG. 2is a top down view of an exemplary embodiment of an absorbent article 10with portions cut away for clarity. FIGS. 3, 4A, 4B, 5, 6A, 6B, 7, 8A,8B, 9A, and 9B provide further illustrations of exemplary embodiments ofan absorbent article 10 with an exudate management layer 40.

The absorbent article 10 can have a longitudinal direction (X), atransverse direction (Y), and a depth direction (Z). The absorbentarticle 10 can have an anterior region 12, a posterior region 14, and acentral region 16 located between the anterior region 12 and theposterior region 14. The absorbent article 10 can have a firsttransverse direction end edge 20, a second transverse direction end edge22 opposed to the first transverse direction end edge 20, and a pair ofopposing longitudinal direction side edges 24 extending between andconnecting the first and second transverse direction end edges, 20 and22. The absorbent article 10 can have a wearer facing, liquid permeabletopsheet layer 30 and a garment facing, liquid impermeable layer 36. Anabsorbent core 38 can be positioned between the topsheet layer 30 andthe liquid impermeable layer 36. The absorbent article 10 can have anexudate management layer 40 in fluid communication with the topsheetlayer 30. In various embodiments, the exudate management layer 40 can bepositioned on a body facing surface 32 of the topsheet layer 30 such as,for example, illustrated in the exemplary embodiments illustrated inFIGS. 3, 4A, 4B, 5, 6A, and 6B. In various embodiments, the exudatemanagement layer 40 can be positioned between the topsheet layer 30 andthe absorbent core 38 such as, for example, illustrated in the exemplaryembodiments illustrated in FIGS. 7, 8A, 8B, 9A, and 9B. The topsheetlayer 30 and the liquid impermeable layer 36 can both extend beyond theoutermost peripheral edges of the absorbent core 38 and can beperipherally bonded together, either entirely or partially, using knownbonding techniques to form a sealed peripheral region. For example, thetopsheet layer 30 and the liquid impermeable layer 36 can be bondedtogether by adhesive bonding, ultrasonic bonding, or any other suitablebonding technique known in the art.

In various embodiments in which the absorbent article 10 is a diaper,training pant, youth pant, swim pant, or an incontinence product such asan adult incontinence pant, the absorbent article 10 can be worn aboutthe lower torso of the wearer and can have a waist opening 230 and legopenings 232.

The absorbent article 10 can have leg elastic members, 240 and 242,which can be bonded to the liquid impermeable layer 36 such as by, forexample, an adhesive, generally adjacent the lateral outer edges of theliquid impermeable layer 36. Alternatively, the leg elastic members, 240and 242, may be disposed between other layers of the absorbent article10. A wide variety of elastic materials may be used for the leg elasticmembers, 240 and 242. Suitable elastic materials can include sheets,strands or ribbons of natural rubber, synthetic rubber, or thermoplasticelastomeric materials. The elastic materials can be stretched andsecured to a substrate, secured to a gathered substrate, or secured to asubstrate and then elasticized or shrunk, for example, with theapplication of heat, such that the elastic retractive forces areimparted to the substrate.

In various embodiments, the absorbent article 10 can have waist elasticmembers, 244 and 246, which can be formed of any suitable elasticmaterial. In such an embodiment, suitable elastic materials can include,but are not limited to, sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers. The elasticmaterials can be stretched and bonded to a substrate, bonded to agathered substrate, or bonded to a substrate and then elasticized orshrunk, for example, with the application of heat, such that elasticretractive forces are imparted to the substrate. It is to be understood,however, that the waist elastic members, 244 and 246, may be omittedfrom the absorbent article 10 without departing from the scope of thisdisclosure.

In various embodiments, the absorbent article 10 can include a fastenersystem. The fastener system can include one or more back fasteners 250and one or more front fasteners 252. Portions of the fastener system maybe included in the anterior region 12, posterior region 14, or both. Thefastener system can be configured to secure the absorbent article 10about the waist of the wearer and maintain the absorbent article 10 inplace during use. In an embodiment, the back fasteners 250 can includeone or more materials bonded together to form a composite ear as isknown in the art. For example, the composite fastener may be composed ofa stretch component 254, a nonwoven carrier or hook base 256, and afastening component 258.

Topsheet Layer:

The topsheet layer 30 defines a body facing surface 32 of the absorbentarticle 10 that may directly contact the body of the wearer and isliquid permeable to receive body exudates. The topsheet layer 30 isdesirably provided for comfort and functions to direct body exudatesaway from the body of the wearer, through its own structure, and towardsthe absorbent core 38. The topsheet layer 30 desirably retains little tono liquid in its structure, so that it provides a relatively comfortableand non-irritating surface next to the skin of the wearer of theabsorbent article 10.

The topsheet layer 30 can be a single layer of material, oralternatively, can be multiple layers that have been laminated together.The topsheet layer 30 can be constructed of any material such as one ormore woven sheets, one or more fibrous nonwoven sheets, one or more filmsheets, such as blown or extruded films, which may themselves be ofsingle or multiple layers, one or more foam sheets, such as reticulated,open cell or closed cell foams, a coated nonwoven sheet, or acombination of any of these materials. Such combination can beadhesively, thermally, or ultrasonically laminated into a unified planarsheet structure to form a topsheet layer 30.

In various embodiments the topsheet layer 30 can be constructed fromvarious nonwoven webs such as meltblown webs, spunbond webs,hydroentangled spunlace webs, or through air bonded carded webs.Examples of suitable topsheet layer 30 materials can include, but arenot limited to, natural fiber webs (such as cotton), rayon,hydroentangled webs, bonded carded webs of polyester, polypropylene,polyethylene, nylon, or other heat-bondable fibers (such as bicomponentfibers), polyolefins, copolymers of polypropylene and polyethylene,linear low-density polyethylene, and aliphatic esters such as polylacticacid. Finely perforated films and net materials can also be used, as canlaminates of/or combinations of these materials. An example of asuitable topsheet layer 30 can be a bonded carded web made ofpolypropylene and polyethylene such as that obtainable from SandlerCorp., Germany. U.S. Pat. Nos. 4,801,494 to Datta, et al., and 4,908,026to Sukiennik, et al., and WO 2009/062998 to Texol teach various othertopsheet materials that may be used as the topsheet layer 30, each ofwhich is hereby incorporated by reference thereto in its entirety.Additional topsheet layer 30 materials can include, but are not limitedto, those described in U.S. Pat. Nos. 4,397,644 to Matthews, et al.,4,629,643 to Curro, et al., 5,188,625 to Van Iten, et al., 5,382,400 toPike, et al., 5,533,991 to Kirby, et al., 6,410,823 to Daley, et al.,and U.S. Publication No. 2012/0289917 to Abuto, et al., each of which ishereby incorporated by reference thereto in its entirety.

In various embodiments, the topsheet layer 30 may contain a plurality ofapertures formed therethrough to permit body exudates to pass morereadily into the absorbent core 38. The apertures may be randomly oruniformly arranged throughout the topsheet layer 30. The size, shape,diameter, and number of apertures may be varied to suit an absorbentarticle's 10 particular needs.

In various embodiments, the tospheet layer 30 can have a basis weightranging from about 5, 10, 15, 20, or 25 gsm to about 50, 100, 120, 125,or 150 gsm. For example, in an embodiment, a topsheet layer 30 can beconstructed from a through air bonded carded web having a basis weightranging from about 15 gsm to about 100 gsm. In another example, atopsheet layer 30 can be constructed from a through air bonded cardedweb having a basis weight from about 20 gsm to about 50 gsm, such as athrough air bonded carded web that is readily available from nonwovenmaterial manufacturers, such as Xiamen Yanjan Industry, Beijing, DaYuanNonwoven Fabrics, and others.

In various embodiments, the topsheet layer 30 can be at least partiallyhydrophilic. In various embodiments, a portion of the topsheet layer 30can be hydrophilic and a portion of the topsheet layer 30 can behydrophobic. In various embodiments, the portions of the topsheet layer30 which can be hydrophobic can be either an inherently hydrophobicmaterial or can be a material treated with a hydrophobic coating.

In various embodiments, the topsheet layer 30 can be a multicomponenttopsheet layer 30 such as by having two or more different nonwoven orfilm materials, with the different materials placed in separatelocations in the transverse direction (Y) of the absorbent article 10.For example, the topsheet layer 30 can be a two layer or multicomponentmaterial having a central portion positioned along and straddling alongitudinal centerline 18 of an absorbent article 10, with lateral sideportions flanking and bonded to each side edge of the central portion.The central portion can be constructed from a first material and theside portions can be constructed from a material which can be the sameas or different from the material of the central portion. In suchembodiments, the central portion may be at least partially hydrophilicand the side portions may be inherently hydrophobic or may be treatedwith a hydrophobic coating. Examples of constructions of multi-componenttopsheet layers 30 are generally described in U.S. Pat. Nos. 5,961,505to Coe, 5,415,640 to Kirby, and 6,117,523 to Sugahara, each of which isincorporated herein by reference thereto in its entirety.

In various embodiments, a central portion of a topsheet layer 30 can bepositioned symmetrically about the absorbent article 10 longitudinalcenterline 18. Such central longitudinally directed central portion canbe a through air bonded carded web (“TABCW”) having a basis weightbetween about 15 and about 100 gsm. Previously described nonwoven,woven, and aperture film topsheet layer materials may also be used asthe central portion of a topsheet layer 30. In various embodiments, thecentral portion can be constructed from a TABCW material having a basisweight from about 20 gsm to about 50 gsm such as is available fromXiamen Yanjan Industry, Beijing, DaYuan Nonwoven Fabrics, and others.Alternatively, aperture films, such as those available from such filmsuppliers as Texol, Italy and Tredegar, U.S.A. may be utilized.Different nonwoven, woven, or film sheet materials may be utilized asthe side portions of the topsheet layer 30. The selection of suchtopsheet layer 30 materials can vary based upon the overall desiredattributes of the topsheet layer 30. For example, it may be desired tohave a hydrophilic material in the central portion andhydrophobic-barrier type materials in the side portions to preventleakage and increase a sense of dryness in the area of the sideportions. Such side portions can be adhesively, thermally,ultrasonically, or otherwise bonded to the central portion along oradjacent the longitudinally directed side edges of the central portion.Traditional absorbent article construction adhesive may be used to bondthe side portions to the central portion. Either of the central portionand/or the side portions may be treated with surfactants and/orskin-health benefit agents, as are well known in the art.

Such longitudinally directed side portions can be of a single ormulti-layered construction. In various embodiments, the side portionscan be adhesively or otherwise bonded laminates. In various embodiments,the side portions can be constructed of an upper fibrous nonwoven layer,such as a spunbond material, laminated to a bottom layer of ahydrophobic barrier film material. Such a spunbond layer may be formedfrom a polyolefin, such as a polypropylene and can include a wettingagent if desired. In various embodiments, a spunbond layer can have abasis weight from about 10 or 12 gsm to about 30 or 70 gsm and can betreated with hydrophilic wetting agents. In various embodiments, a filmlayer may have apertures to allow fluid to permeate to lower layers, andmay be either of a single layer or multi-layer construction. In variousembodiments, such film can be a polyolefin, such as polyethylene havinga basis weight from about 10 to about 40 gsm. Construction adhesive canbe utilized to laminate the spunbond layer to the film layer at anadd-on level of between about 0.1 gsm and 15 gsm. When a film barrierlayer is used in the overall topsheet layer 30 design, it may includeopacifying agents, such as film pigments, that can help the film inmasking stains along the absorbent article 10 side edges, therebyserving as a masking element. In such a fashion, the film layer canserve to limit visualization of a fluid insult stain along the absorbentarticle 10 side edges when viewed from above the topsheet layer 30. Thefilm layer may also serve as a barrier layer to prevent rewet of thetopsheet layer 30 as well as to prevent the flow of fluid off the sideedges of the absorbent article 10. In various embodiments, the sideportions can be laminates such as aspunbond-meltblown-meltblown-spunbond layer (“SMMS”) laminate,spunbond-film laminate, or alternatively, other nonwoven laminatecombinations.

In various embodiments, the topsheet layer 30 can be a fluid entangledlaminate web 160 with projections 162 extending outwardly and away fromat least one intended body-facing surface of the laminate web 160 suchas illustrated in FIGS. 10-12 . In various embodiments, the projections162 can be hollow. The laminate web 160 can have two layers such as asupport layer 164 and a projection layer 166. The support layer 164 canhave a first surface 168 and an opposed second surface 170 as well as athickness 172. The projection layer 166 can have an inner surface 174and an opposed outer surface 176 as well as a thickness 178. Aninterface 180 can be present between the support layer 164 and theprojection layer 166. In various embodiments, fibers of the projectionlayer 166 can cross the interface 180 and be entangled with and engagethe support layer 164 so as to form the laminate web 160. In variousembodiments in which the support layer 164 is a fibrous nonwoven web,the fibers of the support layer 164 may cross the interface 180 and beentangled with the fibers of the projection layer 166.

In various embodiments, the projections 162 can be filled with fibersfrom the projection layer 166 and/or the support layer 164. In variousembodiments, the projections 162 can be hollow. The projections 162 canhave closed ends 182 which can be devoid of apertures. In variousembodiments, however, it may be desirable to create one or moreapertures in each of the projections 162. Such apertures can be formedin the closed ends 182 and/or side walls 184 of the projections 162.Such apertures are to be distinguished from interstitial fiber-to-fiberspacing which is the spacing from one individual fiber to the nextindividual fiber.

In various embodiments, the projections 162 can have a percentage ofopen area in which light can pass through the projections 162 unhinderedby the material forming the projections 162, such as, for example,fibrous material. The percentage of open area present in the projections162 encompasses all area of the projection 162 wherein light can passthrough the projection 162 unhindered. Thus, for example, the percentageof open area of a projection 162 can encompass all open area of theprojection 162 via apertures, interstitial fiber-to-fiber spacing, andany other spacing within the projection 162 where light can pass throughunhindered. In various embodiments, the projections 162 can be formedwithout apertures and the open area can be due to the interstitialfiber-to-fiber spacing. In various embodiments, the projections 162 canhave less than about 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1%open area in a chosen area of the laminate web 160 as measured accordingto the Method to Determine Percent Open Area test method describedherein.

In various embodiments, the shapes of the projections 162, when viewedfrom above, may be, for example, round, oval, square, rectangular,triangular, diamond-shaped, etc. Both the width and the height of theprojections 162 can be varied as can be the spacing and pattern of theprojections 162. In an embodiment, the projections 162 can have aheight, measured according to the Method for Determining Height ofProjections test method described herein, of greater than about 1 mm. Invarious embodiments, the projections 162 can have a height greater thanabout 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm. In various embodiments, theprojections 162 can have a height from about 1, 2, 3, 4, or 5 mm toabout 6, 7, 8, 9, or 10 mm.

The projections 162 of the laminate web 160 can be located on andemanate from the outer surface 176 of the projection layer 166. Invarious embodiments, the projections 162 can extend from the outersurface 176 of the projection layer 166 in a direction away from thesupport layer 164. In various embodiments in which the projections 162can be hollow, they can have open ends 186 which can be located towardsthe inner surface 174 of the projection layer 166 and can be covered bythe second surface 170 of the support layer 164 or the inner surface 174of the projection layer 166 depending upon the amount of fiber that hasbeen used from the projection layer 166 to form the projections 162. Theprojections 162 can be surrounded by land areas 188 which can be formedfrom the outer surface 176 of the projection layer 166 though thethickness of the land areas 188 can be comprised of both the projectionlayer 166 and the support layer 164. The land areas 188 can berelatively flat and planar or topographical variability may be builtinto the land areas 188. For example, in various embodiments, a landarea 188 may have a plurality of three-dimensional shapes formed into itby forming the projection layer 166 on a three-dimensionally-shapedforming surface such as is disclosed in U.S. Pat. No. 4,741,941 toEngelbert, et al. and incorporated herein by reference in its entiretyfor all purposes. For example, in various embodiments, a land area 188may be provided with depressions 190 which can extend all or part wayinto the projection layer 166 and/or support layer 164. In addition, aland area 188 may be subjected to embossing which can impart surfacetexture and other functional attributes to the land area 188. In variousembodiments, a land area 188 and the laminate web 160 as a whole may beprovided with apertures 192 which can extend through the laminate web160 so as to further facilitate the movement of body exudate into andthrough the laminate web 160. Such apertures 192 are to be distinguishedfrom interstitial fiber-to-fiber spacing, which is the spacing from oneindividual fiber to the next individual fiber.

In various embodiments, the land areas 188 can have a percentage of openarea in which light can pass through the land areas 188 unhindered bythe material forming the land areas 188, such as, for example, fibrousmaterial. The percentage of open area present in the land areas 188encompasses all area of the land areas 188 where light can pass throughthe land areas 188 unhindered. Thus, for example, the percentage of openarea of a land area 188 can encompass all open area of the land areas188 via apertures, interstitial fiber-to-fiber spacing, and any otherspacing within the land areas 188 when light can pass throughunhindered. In various embodiments, the land areas 188 can have greaterthan about 1% open area in a chosen area of laminate web 160, asmeasured according to the Method to Determine Percent Open Area testmethod described herein. In various embodiments, the land areas 188 canbe formed without apertures and the open area can be due to theinterstitial fiber-to-fiber spacing. In various embodiments, the landareas 188 can have greater than about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, 18, 19, or 20% open area in a chosen area of thelaminate web 160. In various embodiments, the land areas 188 can haveabout 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9,9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16,16.5, 17, 17.5, 18, 18.5, 19, 19.5, or 20% open area in a chosen area ofthe laminate web 160. In various embodiments, the land areas 188 canhave from about 1, 2, or 3% to about 4 or 5% open area in a chosen areaof the laminate web 160. In various embodiments, the land areas 188 canhave from about 5, 6, or 7% to about 8, 9, or 10% open area in a chosenarea of the laminate web 160. In various embodiments, the land areas 188can have from about 10, 11, 12, 13, 14, or 15% to about 16, 17, 18, 19,or 20% open area in a chosen area of the laminate web 160. In variousembodiments, the land areas can have greater than about 20% open area ina chosen area of the laminate web 160.

The projections 162 of the laminate web 160 can be provided in anyorientation as deemed suitable. In various embodiments, the projections162 of the laminate web 160 can be provided randomly to the laminate web160. In various embodiments, the projections 162 can be orientedlinearly in the longitudinal direction (X) of the absorbent article 10.In various embodiments, the projections 162 can be oriented linearly inthe transverse direction (Y) of the absorbent article 10. In variousembodiments, the projections 162 can be oriented linearly in a directionwhich can be at an angle to the longitudinal direction (X) and/or thetransverse direction (Y) of the absorbent article 10.

The land areas 188 of the laminate web 160 can be provided in anyorientation as deemed suitable. In various embodiments, the land areas188 can be oriented linearly in the longitudinal direction (X) of theabsorbent article 10. In various embodiments, the land areas 188 can beoriented linearly in the transverse direction (Y) of the absorbentarticle 10. In various embodiments, the land areas 188 can be orientedlinearly in a direction which can be at an angle to the longitudinaldirection (X) and the transverse direction (Y) of the absorbent article10.

In various embodiments, the projections 162 and/or the land areas 188can be provided such that the projections 162 are located in the centralregion 16 of the absorbent article 10, are located towards the perimeterof the absorbent article 10, and combinations thereof. In variousembodiments, the projections 162 can have varying heights in differentareas of the absorbent article 10. In such embodiments, for example, theprojections 162 can have a first height in an area of the absorbentarticle 10 and a different height in a different area of the absorbentarticle 10. In various embodiments, the projections 162 can have varyingdiameters in different areas of the absorbent article 10. In suchembodiments, for example, the projections 162 can have a first diameterin an area of the absorbent article 10 and can have a different diameterin another area of the absorbent article 10. In various embodiments, theconcentration of projections 162 can vary in the absorbent article 10.In such embodiments, an area of the absorbent article 10 can have ahigher concentration of projections 162 than the concentration ofprojections 162 in a second area of the absorbent article 10.

While it is possible to vary the density and fiber content of theprojections 162, in various embodiments, the projections 162 can be“hollow.” When the projections 162 are hollow, they can have a shell 194formed from the fibers of the projection layer 166. The shell 194 candefine an interior space 196 which can have a lower density of fibers ascompared to the shell 194 of the projections 162. By “density” it ismeant the fiber count or content per chosen unit of volume within aportion of the interior space 196 or the shell 194 of the projection162. The density of the shell 194 may vary within a particular orindividual projection 162 and it also may vary as between differentprojections 162. In addition, the size of the hollow interior space 196as well as its density may vary within a particular or individualprojection 162 and it also may vary as between different projections162. If there is at least some portion of an interior space 196 of aprojection 162 that has a lower fiber density than at least some portionof the shell 194 of the same projection 162, then the projection 162 isregarded as being “hollow”. In this regard, in some situations, theremay not be a well-defined demarcation between the shell 194 and theinterior space 196 of the projection 162 but, if with sufficientmagnification of a cross-section of one of the projections 162, it canbe seen that at least some portion of the interior space 196 of theprojection 162 has a lower density than some portion of the shell 194 ofthe same projection 162, then the projection 162 is regarded as being“hollow”, If at least a portion of the projections 162 of a laminate web160 are hollow, the projection layer 166 and the laminate web 160 areregarded as being “hollow” or as having “hollow projections”. In variousembodiments, the portion of the projections 162 which are hollow can begreater than or equal to about 50 percent of the projections 162 in achosen area of the laminate web 160. In various embodiments, greaterthan or equal to about 70 percent of the projections 162 in a chosenarea of the laminate web 160 can be hollow. In various embodiments,greater than or equal to about 90 percent of the projections 162 in achosen area of the laminate web 160 can be hollow.

The laminate web 160 can be the result of the movement of the fibers inthe projection layer 166 in one and sometimes two or more directions. Aspreviously noted, the laminate web 160 can be a fluid entangled laminateweb. Referring to FIG. 12 , if the forming surface upon which theprojection layer 166 is placed is solid except for the forming holesused to form the projections 162, then the force of the fluid entanglingstreams hitting and rebounding off the solid surface land areascorresponding to the land areas 188 of the projection layer 166 cancause a migration of fibers adjacent the inner surface 174 of theprojection layer 166 into the support layer 164 adjacent its secondsurface 170. This migration of fibers in the first direction can berepresented by the arrows 198 shown in FIG. 12 . In order to form theprojections 162 extending outwardly from the outer surface 176 of theprojection layer 166, there must be a migration of fibers in a seconddirection as shown by the arrows 200. It is this migration in the seconddirection which causes fibers from the projection layer 166 to move outand away from the outer surface 176 to form the projections 162. Invarious embodiments in which the support layer 164 can be a fibrousnonwoven web, depending on the degree of web integrity and the strengthand dwell time of the fluid jets during the entanglement process, theremay also be movement of support layer 164 fibers into the projectionlayer 166 as shown by arrows 202 in FIG. 12 . The net result of thesefiber movements can be the creation of a laminate web 160 with goodoverall integrity and lamination of the layers (164 and 166) at theirinterface 180 thereby allowing further processing and handling of thelaminate web 160. As a result of the fluid entanglement process tocreate the laminate web 160, it is generally not desirable that thefluid pressure used to form the projections 162 be of sufficient forceso as to force fibers from the support layer 164 to be exposed on theouter surface 176 of the projection layer 166.

The support layer 164 can support the projection layer 166 and can bemade from a number of structures provided the support layer 164 can becapable of supporting the projection layer 166. The primary functions ofthe support layer 164 can be to protect the projection layer 166 duringthe formation of the projections 162, to be able to bond to or beentangled with the projection layer 166 and to aid in further processingof the projection layer 166 and the resultant laminate web 160. Suitablematerials for the support layer 164 can include, but are not limited to,nonwoven fabrics or webs, scrim materials, netting materials,paper/cellulose/wood pulp-based products which can be considered asubset of nonwoven fabrics or webs as well as foam materials, films andcombinations of the foregoing provided the material or materials chosenare capable of withstanding a process of manufacture such as afluid-entangling process. In an embodiment, the support layer 164 can bea fibrous nonwoven web made from a plurality of randomly depositedfibers which may be staple length fibers such as are used, for example,in carded webs, air laid webs, etc. or they may be more continuousfibers such as are found in, for example, meltblown or spunbond webs.Due to the functions the support layer 164 must perform, the supportlayer 164 can have a higher degree of integrity than the projectionlayer 166. In this regard, the support layer 164 can remainsubstantially intact when it is subjected to a fluid-entangling process.The degree of integrity of the support layer 164 can be such that thematerial forming the support layer 164 can resist being driven down intoand filling the projections 162 of the projection layer 166. As aresult, in an embodiment in which the support layer 164 is a fibrousnonwoven web, it should have a higher degree of fiber-to-fiber bondingand/or fiber entanglement than the fibers in the projection layer 166.While it can be desirable to have fibers from the support layer 164entangle with the fibers of the projection layer 166 adjacent theinterface 180 between the two layers, it is generally desired that thefibers of this support layer 164 not be integrated or entangled into theprojection layer 166 to such a degree that large portions of thesefibers find their way inside the projections 162.

In order to resist the higher degree of fiber movement, as mentionedabove, in an embodiment, the support layer 164 can have a higher degreeof integrity than the projection layer 166. This higher degree ofintegrity can be brought about in a number of ways. One can befiber-to-fiber bonding which can be achieved through thermal orultrasonic bonding of the fibers to one another with or without the useof pressure as in through-air bonding, point bonding, powder bonding,chemical bonding, adhesive bonding, embossing, calender bonding, etc. Inaddition, other materials may be added to the fibrous mix such asadhesives and/or bicomponent fibers. Pre-entanglement of a fibrousnonwoven support layer 164 may also be used such as, for example, bysubjecting the web to hydroentangling, needlepunching, etc., prior tothis support layer 164 being joined to a projection layer 166.Combinations of the foregoing are also possible. Still other materialssuch as foams, scrims and nettings may have enough initial integrity soas to not need further processing. The level of integrity can in manycases be visually observed due to, for example, the observation with theunaided eye of such techniques as point bonding which is commonly usedwith fibrous nonwoven webs such as spunbond webs and staplefiber-containing webs. Further magnification of the support layer 164may also reveal the use of fluid-entangling or the use of thermal and/oradhesive bonding to join the fibers together. Depending on whethersamples of the individual layers (164 and 166) are available, tensiletesting in either or both of the machine and cross-machine directionsmay be undertaken to compare the integrity of the support layer 164 tothe projection layer 166. See for example ASTM test D5035-11 which isincorporated herein its entirety for all purposes.

The type, basis weight, tensile strength and other properties of thesupport layer 164 can be chosen and varied depending upon the particularend use of the resultant laminate web 160. When the laminate web 160 isto be used as part of a personal care absorbent article, it can begenerally desirable that the support layer 164 be a layer that is fluidpervious, has good wet and dry strength, is able to absorb fluids suchas body exudates, possibly retain the fluids for a certain period oftime and then release the fluids to one or more subjacent layers. Inthis regard, fibrous nonwovens such as spunbond webs, meltblown webs andcarded webs such as airlaid webs, bonded carded webs and coformmaterials are well-suited as support layers 164. Foam materials andscrim materials are also well-suited. In addition, the support layer 164may be a multi-layered material due to the use of several layers or theuse of multi-bank formation processes as are commonly used in makingspunbond webs and meltblown webs as well as layered combinations ofmeltblown and spunbond webs. In the formation of such support layers164, both natural and synthetic materials may be used alone or incombination to fabricate the materials. In various embodiments, thesupport layer 164 can have a basis weight ranging from about 5 to about40 or 50 gsm.

The type, basis weight and porosity of the support layer 164 can affectthe process conditions necessary to form the projections 162 in theprojection layer 166. Heavier basis weight materials can increase theentangling force of the entangling fluid streams needed to form theprojections 162 in the projection layer 166. However, heavier basisweight support layers 164 can also provide improved support for theprojection layer 166 as the projection layer 166 by itself can be toostretchy to maintain the shape of the projections 162 post the formationprocess. The projection layer 164 by itself can unduly elongate in themachine direction due to the mechanical forces exerted on it bysubsequent winding and converting processes and consequently diminishand distort the projections. Also, without the support layer 164, theprojections 162 in the projection layer 166 tend to collapse due to thewinding pressures and compressive weights the projection layer 166experiences in the winding process and subsequent conversion and do notrecover to the extent they do when a support layer 164 is present.

The support layer 164 may be subjected to further treatment and/oradditives to alter or enhance its properties. For example, surfactantsand other chemicals may be added both internally and externally to thecomponents forming all or a portion of the support layer 164 to alter orenhance its properties. Compounds commonly referred to as hydrogels orsuperabsorbents which absorb many times their weight in liquids may beadded to the support layer 164 in both particulate and fiber form.

The projection layer 166 can be made from a plurality of randomlydeposited fibers which may be staple length fibers such as are used, forexample, in carded webs, airlaid webs, coform webs, etc., or they may bemore continuous fibers such as are found in, for example, meltblown orspunbond webs. The fibers in the projection layer 166 can have lessfiber-to-fiber bonding and/or fiber entanglement and thus less integrityas compared to the integrity of the support layer 164, especially inembodiments when the support layer 164 is a fibrous nonwoven web. In anembodiment, the fibers in the projection layer 166 may have no initialfiber-to-fiber bonding for purposes of allowing the formation of theprojections 162. Alternatively, when both the support layer 164 and theprojection layer 166 can both be fibrous nonwoven webs, the projectionlayer 166 can have less integrity than the support layer 164 due to theprojection layer 166 having, for example, less fiber-to-fiber bonding,less adhesive or less pre-entanglement of the fibers forming theprojection layer 166.

The projection layer 166 can have a sufficient amount of fiber movementcapability to allow a fluid entangling process to be able to move afirst plurality of the plurality of fibers of the projection layer 166out of the X-Y plane of the projection layer 166 and into theperpendicular or Z-direction of the projection layer 166 so as to beable to form the projections 162. As noted herein, in variousembodiments, the projections 162 can be hollow. In an embodiment, asecond plurality of the plurality of fibers in the projection layer 166can become entangled with the support layer 164. If more continuousfiber structures are being used such as meltblown or spunbond webs, inan embodiment, there may be little or no pre-bonding of the projectionlayer 166 prior to the fluid entanglement process. Longer fibers such asare generated in meltblowing and spunbonding processes (which are oftenreferred to as continuous fibers to differentiate them from staplelength fibers) will typically require more force to displace the fibersin the Z-direction than will shorter, staple length fibers thattypically have fiber lengths less than about 100 mm and more typicallyfibers lengths in the 10 to 60 mm range. Conversely, staple fiber webssuch as carded webs and airlaid webs can have some degree of pre-bondingor entanglement of the fibers due to their shorter length. Such shorterfibers require less fluid force from the fluid entangling streams tomove them in the Z-direction to form the projections 162. As a result, abalance must be met between fiber length, degree of pre-fiber bonding,fluid force, web speed and dwell time so as to be able to create theprojections 162 without, unless desired, forming apertures in the landareas 188 or the projections 162 or forcing too much material into theinterior space 196 of the projections 162 thereby making the projections162 too rigid for some end-use applications.

In various embodiments, the projection layer 166 can have a basis weightranging from about 10 gsm to about 60 gsm. Spunbond webs can typicallyhave basis weights of between about 15 and about 50 gsm when being usedas the projection layer 166. Fiber diameters can range between about 5and about 20 microns. The fibers may be single component fibers formedfrom a single polymer composition or they may be bicomponent ormulticomponent fibers wherein one portion of the fiber can have a lowermelting point than the other components so as to allow fiber-to-fiberbonding through the use of heat and/or pressure. Hollow fibers may alsobe used. The fibers may be formed from any polymer formulationstypically used to form spunbond webs. Examples of such polymers include,but are not limited to, polypropylene (“PP”), polyester (“PET”),polyamide (“PA”), polyethylene (“PE”) and polylactic acid (“PLA”). Thespunbond webs may be subjected to post-formation bonding and entanglingtechniques if necessary to improve the processability of the web priorto its being subjected to the projection forming process.

Meltblown webs can typically have basis weights of between about 20 andabout 50 gsm when being used as the projection layer 166. Fiberdiameters can range between about 0.5 and about 5 microns. The fibersmay be single component fibers formed from a single polymer compositionor they may be bicomponent or multicomponent fibers wherein one portionof the fiber can have a lower melting point than the other components soas to allow fiber-to-fiber bonding through the use of heat and/orpressure. The fibers may be formed from any polymer formulationstypically used to form spunbond webs. Examples of such polymers include,but are not limited to, PP, PET, PA, PE and PLA.

Carded and airlaid webs can use staple fibers that can typically rangein length between about 10 and about 100 millimeters. Fiber denier canrange between about 0.5 and about 6 denier depending upon the particularend use. Basis weights can range between about 20 and about 60 gsm. Thestaple fibers may be made from a wide variety of polymers including, butnot limited to, PP, PET, PA, PE, PLA, cotton, rayon, flax, wool, hempand regenerated cellulose such as, for example, Viscose. Blends offibers may be utilized too, such as blends of bicomponent fibers andsingle component fibers as well as blends of solid fibers and hollowfibers. If bonding is desired, it may be accomplished in a number ofways including, for example, through-air bonding, calender bonding,point bonding, chemical bonding and adhesive bonding such as powderbonding. If needed, to further enhance the integrity and processabilityof a projection layer 166 prior to the projection forming process, theprojection layer 166 may be subjected to pre-entanglement processes toincrease fiber entanglement within the projection layer 166 prior to theformation of the projections 162. Hydroentangling can be advantageous inthis regard.

Examples of a laminate web 160 and process for manufacturing a laminateweb 160 can be found in U.S. Pat. No. 9,474,660 to Kirby et al. which ishereby incorporated by reference in its entirety.

Absorbent Core:

An absorbent core 38 can be positioned between the topsheet layer 30 andthe liquid impermeable layer 36 of the absorbent article 10. Theabsorbent core 38 can generally be any single layer structure orcombination of layer components, which can demonstrate some level ofcompressibility, conformability, be non-irritating to the wearer's skin,and capable of absorbing and retaining liquids and other body exudates.In various embodiments, the absorbent core 38 can be formed from avariety of different materials and can contain any number of desiredlayers. For example, the absorbent core 38 can include one or morelayers (e.g., two layers) of absorbent web material of cellulosic fibers(e.g., wood pulp fibers), other natural fibers, synthetic fibers, wovenor nonwoven sheets, scrim netting, or other stabilizing structures,superabsorbent material, binder materials, surfactants, selectedhydrophobic and hydrophilic materials, pigments, lotions, odor controlagents or the like, as well as combinations thereof. In an embodiment,the absorbent web material can include a matrix of cellulosic fluff andcan also include superabsorbent material. The cellulosic fluff cancomprise a blend of wood pulp fluff. An example of wood pulp fluff canbe identified with the trade designation NB416, available fromWeyerhaeuser Corp., and is a bleached, highly absorbent wood pulpcontaining primarily soft wood fibers.

In various embodiments, if desired, the absorbent core 38 can include anoptional amount of superabsorbent material. Examples of suitablesuperabsorbent material can include poly(acrylic acid), poly(methacrylicacid), poly(acrylamide), poly(vinyl ether), maleic anhydride copolymerswith vinyl ethers and α-olefins, poly(vinyl pyrrolidone),poly(vinylmorpholinone), poly(vinyl alcohol), and salts and copolymersthereof. Other superabsorbent materials can include unmodified naturalpolymers and modified natural polymers, such as hydrolyzedacrylonitrile-grafted starch, acrylic acid grafted starch, methylcellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose,and natural gums, such as alginates, xanthan gum, locust bean gum, andso forth. Mixtures of natural and wholly or partially syntheticsuperabsorbent polymers can also be useful. The superabsorbent materialcan be present in the absorbent core 38 in any amount as desired.

Regardless of the combination of absorbent materials used in theabsorbent core 38, the absorbent materials can be formed into a webstructure by employing various conventional methods and techniques. Forexample, the absorbent web can be formed by techniques such as, but notlimited to, a dry-forming technique, an air forming technique, a wetforming technique, a foam forming technique, or the like, as well ascombinations thereof. A coform nonwoven material can also be employed.Methods and apparatus for carrying out such techniques are well known inthe art.

The shape of the absorbent core 38 can vary as desired and can compriseany one of various shapes including, but not limited to, triangular,rectangular, dog-bone, elliptical, trapezoidal, T-shape, I-shape, andhourglass shapes. In various embodiments, the absorbent core 38 can havea shape that generally corresponds with the overall shape of theabsorbent article 10. The dimensions of the absorbent core 38 can besubstantially similar to those of the absorbent article 10, however, itwill be appreciated that the dimensions of the absorbent core 38 whilesimilar, will often be less than those of the overall absorbent article10, in order to be adequately contained therein. The size and theabsorbent capacity of the absorbent core 38 should be compatible withthe size of the intended wearer and the liquid loading imparted by theintended use of the absorbent article 10. Additionally, the size and theabsorbent capacity of the absorbent core 38 can be varied to accommodatewearers ranging from infants to adults.

The absorbent core 38 can have a length ranging from about 120, 125,130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 225, 230, 240, 250,260, 270, 280, 290, 300, 310, 320, 330, 340, or 350 mm to about 355,360, 380, 385, 390, 395, 400, 410, 415, 420, 425, 440, 450, 460, 480,500, 510, 520, 530, 540, 550, 600, 610, 620, or 630 mm. The absorbentcore 38 may have a width in the central region 16 ranging from about 30,40, 50, 55, 60, 65, or 70 mm to about 75, 80, 85, 90, 95, 100, 105, 110,115, 120, 125, 130, 140, 150, 160, 170 or 180 mm. The width of theabsorbent core 38 located within the anterior region 12 and/or posteriorregion 14 of the absorbent article 10 may range from about 50, 55, 60,65, 70, 75, 80, 85, 90, or 95 mm to about 100, 105, 110, 115, 120, 125or 130 mm. As noted herein, the absorbent core 38 can have a length andwidth that can be less than or equal to the length and width of theabsorbent article 10.

In an embodiment, the absorbent article 10 can be a diaper having thefollowing ranges of lengths and widths of an absorbent core 38 having anhourglass shape: the length of the absorbent core 38 may range fromabout 170, 180, 190, 200, 210, 220, 225, 240 or 250 mm to about 260,280, 300, 310, 320, 330, 340, 350, 355, 360, 380, 385, or 390 mm; thewidth of the absorbent core 38 in the central region 16 may range fromabout 40, 50, 55, or 60 mm to about 65, 70, 75, or 80 mm; the width ofthe absorbent core 38 in the anterior region 12 and/or the posteriorregion 14 may range from about 80, 85, 90, or 95 mm to about 100, 105,or 110 mm.

In an embodiment, the absorbent article 10 may be a training pant oryouth pant having the following ranges of lengths and widths of anabsorbent core 38 having an hourglass shape: the length of the absorbentcore 38 may range from about 400, 410, 420, 440 or 450 mm to about 460,480, 500, 510 or 520 mm; the width of the absorbent core 38 in thecentral region 16 may range from about 50, 55, or 60 mm to about 65, 70,75, or 80 mm; the width of the absorbent core 38 in the anterior region12 and/or the posterior region 14 may range from about 80, 85, 90, or 95mm to about 100, 105, 110, 115, 120, 125, or 130 mm.

In an embodiment, the absorbent article 10 can be an adult incontinencegarment having the following ranges of lengths and widths of anabsorbent core 38 having a rectangular shape: the length of theabsorbent core 38 may range from about 400, 410 or 415 to about 425 or450 mm; the width of the absorbent core 38 in the central region 16 mayrange from about 90, or 95 mm to about 100, 105, or 110 mm. It should benoted that the absorbent core 38 of an adult incontinence garment may ormay not extend into either or both the anterior region 12 or theposterior region 14 of the absorbent article 10.

In an embodiment, the absorbent article 10 can be a feminine hygieneproduct having the following ranges of lengths and widths of anabsorbent body 40 having an hourglass shape: the length of the absorbentcore 38 may range from about 150, 160, 170, or 180 mm to about 190, 200,210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310 or 320 mm; thewidth of the absorbent core 38 in the central region 16 may range fromabout 30, 40, or 50 mm to about 60, 70, 80, 90 or 100 mm.

By way of example, suitable materials and/or structures for theabsorbent core 38 can include, but are not limited to, those describedin U.S. Pat. Nos. 4,610,678 to Weisman, et al., 6,060,636 to Yahiaoui,et al., 6,610,903 to Latimer, et al., 7,358,282 to Krueger, et al., andU.S. Publication No. 2010/0174260 to Di Luccio, et al. each of which ishereby incorporated by reference thereto in its entirety.

In various embodiments, an absorbent core 38 can be a single layerstructure and can include, for example, a matrix of cellulosic fluff andsuperabsorbent material. In various embodiments, an absorbent core 38can have at least two layers of material, such as, for example, a bodyfacing layer and a garment facing layer. In various embodiments, the twolayers can be identical to each other. In various embodiments, the twolayers can be different from each other. In such embodiments, the twolayers can provide the absorbent article 10 with different absorptionproperties as deemed suitable. In various embodiments, the body facinglayer of the absorbent core 38 may be constructed of an airlaid materialand the garment facing layer of the absorbent core 38 may be constructedof a superabsorbent polymer-containing compressed sheet. In suchembodiments, the airlaid material can have a basis weight from about 40to about 200 gsm and the superabsorbent polymer-containing compressedsheet can be a cellulosic fluff based material that can be a combinationof cellulosic pulp and SAP enclosed with a tissue carrier and having abasis weight from about 40 to about 400 gsm.

Liquid Impermeable Layer:

The liquid impermeable layer 36 is generally liquid impermeable and isthe portion of the absorbent article 10 which faces the garments of thewearer. The liquid impermeable layer 36 can permit the passage of air orvapor out of the absorbent article 10 while still blocking the passageof liquids. Any liquid impermeable material may generally be utilized toform the liquid impermeable layer 36. The liquid impermable layer 36 canbe composed of a single layer or multiple layers, and these one or morelayers can themselves comprise similar or different materials. Suitablematerial that may be utilized can be a microporous polymeric film, suchas a polyolefin film or polyethylene or polypropylene, nonwovens, andnonwoven laminates, and film/nonwoven laminates. The particularstructure and composition of the liquid impermeable layer 36 can beselected from various known films and/or fabrics with the particularmaterial being selected as appropriate to provide the desired level ofliquid barrier, strength, abrasion resistance, tactile properties,aesthetics, and so forth. In various embodiments, a polyethylene filmcan be utilized that can have a thickness in the range of from about 0.2or 0.5 mils to about 3.0 or 5.0 mils. An example of a liquid impermeablelayer 36 can be a polyethylene film such as that obtainable from PliantCorp., Schaumburg, Ill., USA. Another example can include calciumcarbonate-filled polypropylene film. In still another embodiment, theliquid impermeable layer 36 can be a hydrophobic nonwoven material withwater barrier properties such as a nonwoven laminate, an example ofwhich can be a spunbond, meltblown, meltblown, spunbons, four-layeredlaminate.

In various embodiments, the liquid impermeable layer 36 can be a twolayer construction, including an outer layer material and an inner layermaterial which can be bonded together. The outer layer can be anysuitable material and may be one that provides a generally cloth-liketexture or appearance to the wearer. An example of such material can bea 100% polypropylene bonded-carded web with a diamond bond patternavailable from Sandler A.G., Germany, such as 30 gsm Sawabond 4185® orequivalent. Another example of material suitable for use as an outerlayer can be a 20 gsm spunbond polypropylene non-woven web. The innerlayer can be either vapor permeable (i.e., “breathable”) or vaporimpermeable. The inner layer may be manufactured from a thin plasticfilm, although other liquid impermeable materials may also be used. Theinner layer can inhibit liquid body exudates from leaking out of theabsorbent article 10 and wetting articles, such as bed sheets andclothing, as well as the wearer and caregiver. An example of a materialfor an inner layer can be a printed 19 gsm Berry Plastics XP-8695H filmor equivalent commercially available from Berry Plastics Corporation,Evansville, Ind., U.S.A.

The liquid impermeable layer 36 can, therefore, be of a single ormultiple layer construction, such as of multiple film layers orlaminates of film and nonwoven fibrous layers. Suitable liquidimpermeable layers 36 can be constructed from materials such as thosedescribed in U.S. Pat. Nos. 4,578,069 to Whitehead, et al., 4,376,799 toTusim, et al., 5,695,849 to Shawver, et al., 6,075,179 to McCormack, etal., and 6,376,095 to Cheung, et al., each of which are herebyincorporated by reference thereto in its entirety.

Exudate Management Layer:

In various embodiments, the absorbent article 10 can have an exudatemanagement layer 40 in fluid communication with the topsheet layer 30.In various embodiments, such as, for example, illustrated in FIGS. 3,4A, 4B, 5, 6A, and 6B, the exudate management layer 40 can be positionedon the body facing surface 32 of the topsheet layer 30. In variousembodiments, such as, for example, illustrated in FIGS. 7, 8A, 8B, 9A,and 9B, the exudate management layer 40 can be positioned between thetopsheet layer 30 and the absorbent core 38.

In various embodiments, the exudate management layer 40 can be made of amaterial that can be capable of transferring, in the depth direction(Z), body exudates that are delivered to the topsheet layer 30. Any of avariety of materials can be utilized as the exudate management layer 40.

In various embodiments, the material can be synthetic, cellulosic, or acombination of synthetic and cellulosic materials. In variousembodiments, the exudate management layer 40 can be constructed fromwoven or nonwoven materials. For example, the exudate management layer40 can be constructed as an airlaid or a TABCW material. For example,airlaid cellulosic tissues may be suitable for use in the exudatemanagement layer 40. The airlaid cellulosic tissue may have a basisweight ranging from about 10 or 100 gsm to about 250 or 300 gsm. Theairlaid cellulosic tissue can be formed from hardwood and/or softwoodfibers. An airlaid cellulosic tissue can have a fine pore structure andcan provide an excellent wicking capacity.

In various embodiments, a foam material can be utilized to form theexudate management layer 40. In various embodiments, the foam materialcan be an open-cell or porous foam. The physical properties of the foammaterial as well as its wettability and fluid management properties canbe tailored to meet the specific characteristics desired for the usageof a foam material in the absorbent article 10. In various embodiments,the foam material can be moisture stable and not degrade or collapse andlose its structure and fluid management properties when exposed to bodyexudate. In various embodiments, the foam material can be an open-cellfoam, a closed cell foam, or a partially open-cell foam that is either athermoplastic or thermoset material. A foam material can be manufacturedby extrusion or casting and coating processes including frothed foam,aerated foam, and emulsion foam methods. Such foams can be manufacturedfrom different polymer chemistries to achieve the desired softness,flexibility, and resilience of the foam material when utilized in anabsorbent article 10. In various embodiments, the foam material can bebased on organic or inorganic chemistries and can also be based upon afoam material obtained from natural sources. In various embodiments, thefoam material can have a polymer chemistry which can be a polyurethanefoam, polyolefin foam, poly(styrene-butadiene) foam, poly(ethylene-vinylacetate) foam, or a silicone based foam. Other polymer chemistries knownto one of ordinary skill in the art could be used along with additivessuch as plasticizers, opacifiers, colorants, antioxidants, andstabilizers to obtain the desired foam properties. In variousembodiments, the viscoelastic properties could be modified to obtain adesired response to applied load from the foam material includingproperties similar to that commonly referred to as polyurethane memoryfoam materials. In various embodiments, the Poisson's ratio of the foammaterial could be modified to obtain the desired response from the foammaterial to applied stress and foam materials with auxetic propertiescould be considered if desired.

In various embodiments in which a foam material is utilized for theexudate management layer, the foam material can have material propertiesto enable cutting of the foam material such as, for example, with amechanical die, such as foam materials which are referred to asclickable foams in the polyurethane foam industry. In variousembodiments, the foam material can also be selected to enable othermethods of cutting the foam material including, but not limited to,laser die cutting and water jet cutting. In various embodiments, thefoam material can be tailored to enable perforating the foam materialutilizing mechanical dies and cutting or hole-punching devices and canalso be capable of achieving the perforation utilizing ultrasonicprocesses.

A porous foam material can have pores which can vary in size and/ordistribution. In various embodiments, a pore size of a foam material canbe from about 10 microns to about 350 microns. In various embodiments,the foam material can have a multimodal pore size distribution in orderto handle a variety of components within the body exudates. In variousembodiments, a multimodal pore size distribution can be achieved withinthe same monolithic foam structure or could be achieved by using layersof foam material with a narrow pore size distribution which whencombined into a single foam material would allow a multimodal pore sizedistribution to be achieved for the combination of layers.

In various embodiments, the foam material can be a polyesterpolyurethane foam material. In various embodiments, the average cellsize of the foam material can be from about 100, 150, or 200 microns toabout 250, 300, or 350 microns. The number of open cells in the foammaterial can provide the foam material with measurement of the foammaterial's porosity. The porosity of the foam material is measured inpores per linear inch (ppi) and refers to the number of pores in onelinear inch of a two-dimensional planar foam material surface and isdescribed by the Polyurethane Foam Association. The pores per linearinch is measured by counting the pores visually under a microscope usinga grid. The smaller the ppi value of the foam material the larger thepore size, and vice versa. In various embodiments, the foam material canhave a porosity from about 20 or 40 ppi to about 55, 65, or 90 ppi. Invarious embodiments in which an open-cell foam material is utilized, thefoam material can be substantially open-cell or of a completelyreticulated structure. The reticulation of the foam material can beachieved by several methods known to one skilled in the art include foammade by in-situ reticulation processes during foam formation. Thereticulated foam material can also be made by treating a substantiallyopen-cell foam material to a high pressure fluid stream to remove thecell walls of the foam material. In general, foam materials are capableof stretching, however, in various embodiments the foam material canhave a reduced elongation capacity. In various embodiments, the foammaterial can have a low elongation, such as, for example, less than a200% elongation at break. In various embodiments, the foam material hasan elongation at break from about 80 or 100% to about 150 or 200%. Invarious embodiments, the basis weight of the foam material can be fromabout 45 gsm to about 50 or 55 gsm. In various embodiments, the densityof the foam material can be from about 0.01, 0.02 or 0.03 g/cc to about0.05 or 0.08 g/cc. The foam material can also have a compression modulusthat allows it to be soft and flexible when used in an absorbentarticle. In various embodiments, the foam material can have acompression force deflection at 25% deflection from about 0.5 or 0.6 psito about 0.8 or 1.0 psi.

The foam material can be either hydrophilic or hydrophobic dependentupon the desired properties of the foam material in the absorbentarticle 10. In various embodiments the foam material can be ahydrophilic foam material. In various embodiments, the foam material canbe hydrophobic and can be treated with a surfactant to create ahydrophilic foam material. In various embodiments, for example, thematerial utilized to form the exudate management layer 40 can be ahydrophobic, open-cell, polyurethane foam treated with from about 0.3%or 0.8% to about 1.6, 2.0, or 3.0% of a surfactant. In variousembodiments, the surfactant utilized to treat the foam material can be anonionic surfactant such as a nonionic surfactant comprising at least anethoxylated linear oleochemical alcohol such as an alkylphenolethoxylate, such as LUTENSOL® A65N, commercially available from BASF, oran ethoxylated acetylenic diol such as SURFYNOL® 465, commerciallyavailable from Air Products, Allentown, Pa. In various embodiments, thehydrophilicity of the foam material, as a result of the surfactanttreatment, can be uniform in the longitudinal direction (X) and thetransverse direction (Y) of the foam material. In various embodiments,the hydrophilicity of the foam material, as a result of the surfactanttreatment, can vary in the longitudinal direction (X), in the transversedirection (Y), or in both of the longitudinal direction (X) and thetransverse direction (Y). In various embodiments, the polymer utilizedto formulate the foam material can be selected to have the desiredhydrophilic properties. In various embodiments, this can be achieved byusing an inherently hydrophilic polymer that is wettable by aqueousfluids or by including additives in the polymer during formation of thefoam material. These additives can make the foam material wettable toaqueous fluids even if the base polymer of the foam material ishydrophobic. A non-limiting example of such an approach can be toinclude polyethylene glycol as an additive with a hydrophobic polymer.

In various embodiments, the foam material can be hydrophobic and canhave hydrophilic fibers inserted into the foam material to create ahydrophilic foam and fiber composite. The hydrophilic fibers within thefoam material can provide a hydrophilic pathway through the foammaterial to direct body exudates through the foam material. Referring toFIGS. 13, 14, and 15 , FIG. 13 is a photomicrograph (taken by scanningelectron microscope at a magnification of 100×) of a cross-sectionalview of a portion of a foam and fiber composite material 100 suitablefor use as the exudate management layer 40, FIG. 14 is a photomicrograph(taken by scanning electron microscope at a magnification of 40×) of aplanar view of the foam and fiber composite material 100 of FIG. 13 suchthat the fibrous material is visible to the viewer, and FIG. 15 is aphotomicrograph (taken by scanning electron microscope at amagnification of 40×) of a planar view of the foam and fiber composite100 of FIG. 13 such that the second planar surface of the foam materialand portions of fibers are visible to the viewer. As is visible in FIGS.13, 14, and 15 , the foam and fiber composite material 100 can be formedof an open-cell foam material 110 and a fibrous material 120. The foammaterial 110 can have a first planar surface 112 and a second planarsurface 114. In FIG. 13 , each planar surface, 112 and 114, have beendelineated by the corresponding broken lines for visual clarity. A layerof fibrous material 120 is in contact with one of the planar surfaces,such as planar surface 112, of the foam material 110. The layer offibrous material 120 is formed from a plurality of individual fibers122. As is visible in the foam and fiber composite material 100 shown inFIG. 13 , a portion of the individual fibers 122 can extend from thefibrous material 120 and through the foam material 110 from the firstplanar surface 112 of the foam material 110 to the second planar surface114 of the foam material 110. The foam and fiber composite 100 can havea total basis weight from about 20 gsm to about 250 gsm. The amount offibrous material 120, including individual fibers 122 which are withinthe foam material, is at least about 10% of the total basis weight ofthe foam and fiber composite 100. In various embodiments, at least about2, 5, 10, 15, 20, 30, 40, 50, 60 or 70 gsm of fibrous material 120 isbrought into contact with a planar surface, such as planar surface 112of the foam material 110. In various embodiments, the fibrous material120 can be formed from a plurality of individual fibers 122. In variousembodiments, the individual fibers 122 of the fibrous material 120 canbe a loose configuration such as may occur with wet-laying or air-layingof the fibrous material 120. In various embodiments, the individualfibers 122 of the fibrous material 120 can be in the form of a nonwovenweb of material such as, for example, a carded nonwoven web. The fibrousmaterial 120 can, therefore, be manufactured via various processes suchas, but not limited to, air-laying, wet-laying, and carding. In variousembodiments, the fibers 122 forming the fibrous material 120 can behydrophilic. The fibers 122 can be naturally hydrophilic or can befibers which are naturally hydrophobic but which have been treated to behydrophilic, such as, for example, via a treatment with a surfactant.Providing hydrophilic fibers 122 can allow for a foam and fibercomposite 100 which can have hydrophilic pathways through the foammaterial 110. In various embodiments in which the foam material 110 ishydrophobic, the hydrophilic pathways provided by the hydrophilic fibers122 can allow for the foam and fiber composite 100 in an absorbentarticle 10 to intake bodily exudates (via the hydrophilic fiberpathways) and maintain the body exudates in a location away from thetopsheet layer 30 of the absorbent article 10 as the body exudates willnot be able to readily pass through the hydrophobic foam material 110.In various embodiments, the fibers 122 forming the fibrous material 120can be cellulosic fibers such as, but not limited to, cotton, ramie,jute, hemp, flax, bagasse, northern softwood kraft pulp, as well assynthetic cellulosic fibers such as, but not limited to, rayon, viscose,and cellulosic acetate. In various embodiments, the fibers 122 formingthe fibrous material 120 can be synthetic fibers made from polymers suchas polyethylene, polypropylene, aromatic polyesters, aliphaticpolyesters, and polyamides. In such embodiments, the fibers 122 can betreated with additives to impart various degrees of surface energyranging from very low surface energy and low wettability to high surfaceenergy and high wettability.

The exudate management layer 40 is formed from a base sheet of material,such as any of the materials described above, and is configured to havea first component 50 which at least partially defines an opening 42 fordirect passage of body exudates into the absorbent core 38 and a secondcomponent 60 connected to the first component 50. The first component 50can provide the exudate management layer 40 with a first heightdimension 76 and the second component 60 can provide the exudatemanagement layer 40 with a second height dimension 78 that can begreater than the first height dimension 76.

The first component 50 of the exudate management layer 40 can have afirst transverse direction end edge 52, a second transverse directionend edge 54, and an opposing pair of longitudinal direction side edges56 extending between and connecting the transverse direction end edges,52 and 54. The first component 50 can generally have any shape and/orsize desired. In various embodiments, for example, the first component50 can have a rectangular shape, a curved rectangular shape, an ovalshape, an elliptical shape, a circular shape, an hourglass shape, asquare shape, or a curved square shape. In various embodiments, each ofthe edges, 52, 54, and 56, of the first component 50 can be straight. Invarious embodiments, at least one of the edges, 52, 54, or 56, of thefirst component 50 can be arcuate and the remaining edges can bestraight. In various embodiments, at least two of the edges, 52, 54, or56, of the first component 50 can be arcuate and the remaining edges canbe straight. In various embodiments, for example, the longitudinaldirection side edges 56 of the first component 50 can be straight andthe transverse direction end edges, 52 and 54, can be arcuate. Invarious embodiments, the transverse direction end edges, 52 and 54, canhave an arcuate shape which can form a complementary configuration witheach other if the two edges, 52 and 54, were to be brought together. Invarious embodiments, at least three of the edges, 52, 54, or 56, of thefirst component 50 can be arcuate and the remaining edge can bestraight. In various embodiments, all of the edges, 52, 54, and 56, ofthe first component 50 can be arcuate.

In various embodiments, the first component 50 can have a longitudinaldirection length as measured from the first transverse direction endedge 52 to the second transverse direction end edge 54 which can be lessthan the overall length of the absorbent article 10. For example, thefirst component 50 can have a longitudinal length between about 20, 30,40, 50, or 60 mm to about 100, 150, 175, 200, 250, or 300 mm. In variousembodiments, the first component 50 can have a longitudinal directionlength that is from about 15, 20, 25, 30, 35, or 40% to about 50, 55,60, 65, 70, 75, 80, 85, or 90% of the longitudinal length of theabsorbent article 10. In various embodiments, the first component 50 canhave a transverse width as measured form a first longitudinal directionside edge 56 to a second longitudinal direction side edge 56 which canbe equal to or less than the overall width of the absorbent article 10.For example, the first component 50 can have a transverse width betweenabout 10, 15, 20, or 30 mm to about 60, 80, 100, 110, 115, 120, 125,130, 140, or 150 mm. In various embodiments, the first component 50 canhave a transverse width that is from about 15, 20, 25, 30, 35, of 40% toabout 50, 55, 60, 65, 70, 75, 80, 85, or 90% of the transverse width ofthe absorbent article 10. The first component 50 has a body facingsurface 72 and a garment facing surface 74. The first component 50 canprovide the exudate management layer 40 with a first height dimension 76in the depth direction (Z) of the exudate management layer 40. Invarious embodiments, the first height dimension 76 can be from about0.5, 0.75, 1, 1.5, 2, or 3.5 mm to about 3, 3.5, 4, 4.5, 5, 6, or 10 mm.

To enhance the ability of the absorbent article 10 to transfer bodyexudates in the depth direction (Z) as well as to enhance the ability ofthe exudate management layer 40 to conform to the wearer's body based onits ability to bend, the first component 50 of the exudate managementlayer 40 can have an opening 42 which can be any suitable shape, suchas, but not limited to, ovular, circular, rectangular, square,elliptical, hourglass, triangular, etc. In various embodiments, theshape of the opening 42 can include a shape of a physical object, suchas, for example, the outer shape of a leaf, an animal, a star, a heart,a tear drop, a moon, or an abstract configuration. In variousembodiments, the opening 42 in the first component 50 can be elongateand can be oriented in the longitudinal direction (X) of the absorbentarticle 10. The opening 42 can be bounded at least partially by aperimeter 44, which can form an inner border or inner edge of the firstcomponent 50, and bounded at least partially by a primary fold 70connecting the first component 50 to a second component 60 of theexudate management layer 40. The opening 42 passes through the firstcomponent 50 from the body facing surface 72 of the first component tothe garment facing surface 74 of the first component 50. The opening 42can form a cup or well-like structure for holding body exudates andpreventing its leakage away from a region of the absorbent article 10and towards the edges of the absorbent article 10.

The opening 42 can be located at various positions along thelongitudinal and transverse directions of the absorbent article 10depending upon the primary location of body exudate intake within theabsorbent article 10. This variability in positioning allows the opening42 to be positioned below the main point of body exudate discharge sothat it can act as the primary body exudate receiving area for theabsorbent article 10. For example, in various embodiments, the absorbentarticle 10 can have a longitudinal centerline 18 and a transversecenterline 80. It should be understood that the longitudinal centerline18 is disposed at a distance that is equidistant from the longitudinaldirection side edges 24 and runs the length of the absorbent article 10in the longitudinal direction (X), while the transverse centerline 80 isdisposed at a location that is equidistant from the first transversedirection end edge 20 and the second transverse direction end edge 22and runs along the width of the absorbent article 10 in the transversedirection (Y). In various embodiments, the opening 42 of the exudatemanagement layer 40 can be positioned so that it is in symmetricalalignment with the longitudinal centerline 18 and the transversecenterline 80 of the absorbent article 10. This allows the opening 42 tobe centrally disposed within the absorbent article 10. However,centralized positioning of the opening 42 in the absorbent article 10 isnot required and, in various embodiments, depending on the primarylocation where body exudate intake might occur within the absorbentarticle 10, the opening 42 of the exudate management layer 40 may beeither symmetrical about the longitudinal centerline 18 only or may notbe symmetrical about either the longitudinal centerline 18 or thetransverse centerline 80. In various embodiments, it may be desirablefor the opening 42 to be shifted in the longitudinal direction (X)towards the posterior region 14 transverse direction end edge 22 toprovide an absorbent article 10 with an improved ability to receive andisolate body exudate such as fecal material. Providing an absorbentarticle 10 with a structure that can receive and isolate fecal materialcan reduce the incidence of the fecal material contacting the wearer'sgenitalia as well as reduce the incidence of leakage of the fecalmaterial from the absorbent article 10. In various embodiments, theopening 42 of the exudate management layer 40 may be symmetrical aboutthe longitudinal centerline 18 and asymmetrical about the transversecenterline 80. In various embodiments, the opening 42 of the exudatemanagement layer 40 may be asymmetrical about each of the longitudinalcenterline 18 and the transverse centerline 80. In various embodiments,the opening 42 of the exudate management layer 40 can be positionedbetween the transverse centerline 80 and the posterior region 14transverse direction end edge 22 of the absorbent article 10. In suchembodiments, the opening 42 of the exudate management layer 40 may ormay not be symmetrical about the longitudinal centerline 18.

The opening 42 in the exudate management layer 40 can have alongitudinal length from about 15, 20, 30, or 50 mm to about 60, 75,100, or 150 mm and can have a transverse width from about 10, 15, 20, or30 mm to about 40, 60, 80, 100, 110, 120, or 130 mm. The opening 42 inthe exudate management layer 40 can have a longitudinal length that isfrom about 15, 20, or 25% to about 70, 75, or 80% of the overalllongitudinal length of the first component 50 in the longitudinaldirection (X). The opening 42 in the exudate management layer 40 canhave a transverse width that can be from about 20, 25, or 30% to about70, 75, or 80% of the overall width of the first component 50 in thetransverse direction (Y). The opening 42 of the exudate management layer40 can be sized as deemed suitable for the receipt and isolation offecal material within the absorbent article 10.

In addition to the first component 50, the exudate management layer 40has a second component 60 which is in an at least partially overlappingconfiguration with the first component 50. The second component 60 isformed from the same base sheet of material forming the first component50 of the exudate management layer 40 and is connected to the firstcomponent 50 via a primary fold 70 in the material forming the exudatemanagement layer 40. The second component 60 of the exudate managementlayer 40 extends from the primary fold 70 in the longitudinal direction(X) of the absorbent article 10 in a direction towards the posteriorregion 14 of the absorbent article 10. The second component 60 can helpshape the absorbent article 10, create a close-to-body fit, and absorbfluid from a wearer's buttock's region. In various embodiments, thesecond component 60 can extend beyond the second transverse directionend edge 54 of the first component 50. In various embodiments, thesecond component 60 may not extend beyond the second transversedirection end edge 54 of the first component 50.

The second component 60 can have a first transverse direction end edge62 which is coextensive with the primary fold 70, a second transversedirection end edge 64 and an opposing pair of longitudinal directionside edges 66 extending between and connecting the transverse directionend edges, 62 and 64. The second component 60 can generally have anyshape and/or size desired. The second component 60 is created bycutting, punching, or otherwise separating the material forming thesecond component 60 from the material forming the first component 50.Such cutting, punching, or otherwise separating of the second component60 from the first component 50 will result in the perimeter 44 which atleast partially defines the opening 42 in the first component 50. Thesecond component 60 is positioned into an at least partially overlappingconfiguration with the first component 50 by incorporating a primaryfold 70 into the material forming the exudate management layer 40. Thesecond component 60 is not fully separated from the first component 50and remains attached to the first component 50 via the primary fold 70.In various embodiments, as the formation of the second component 60results in the formation of the opening 42, the second component 60 canhave a shape and size which can be considered a mate of and iscomplementary to the shape and size of the opening 42. In suchembodiments, the second component 60 therefore, when not in an at leastpartially overlapping configuration with the first component 50, can fitentirely within the opening 42 of the exudate management layer 40 andthe edges, 64 and 66, of the second component 60 can be adjacent to theperimeter 44 of the first component 50. In various embodiments, thesecond component 60 can be smaller in dimension than the opening 42,such as, for example, if the second component 60 is further reduced insize dimension. In such embodiments, the second component 60 can fitentirely within the opening 42 of the exudate management layer 40 butthe edges of the second component 60 may not be adjacent to theperimeter 44 of the first component 50. In various embodiments, aportion of the second component 60 may be removed from the secondcomponent 60 as part of the cutting or punching to form the secondcomponent 60 such that the second component 60 is not a perfect mate oris not exactly complementary to the shape and size of the opening 42.

The second component 60 can have a longitudinal length from about 15,20, 30, or 50 mm to about 60, 75, 100, or 150 mm and can have atransverse width from about 10, 15, 20, or 30 mm to about 40, 60, 80,100, 110, 120, or 130 mm. In various embodiments, the second component60 can have a longitudinal direction length that is from about 15, 20,25, 30, 35, or 40% to about 50, 55, 60, 65, 70, 75, 80, 85, or 90% ofthe longitudinal length of the first component 50. In variousembodiments, the second component 60 can have a transverse width that isfrom about 15, 20, 25, 30, 35, or 40% to about 50, 55, 60, 65, 70, 75,80, 85, or 90% of the transverse width of the first component 50. Invarious embodiments, the second transverse direction end edge 64 of thesecond component 60 can be from about 15 mm to about 75 mm from thesecond transverse direction end edge 22 of the absorbent article 10. Thesecond component 60 can provide a height dimension 78 to the exudatemanagement layer 40 and the second height dimension 78, in the depthdirection (Z), can be from about 0.5, 0.75, 1, 1.5, 2, 3, 3.5, 4, 4.5,5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or 10 mm to about 10.5, 11,11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18,18.5, 19, 19.5, or 20 mm.

The first component 50 and the second component 60 can be in an at leastpartially overlapping configuration with each other. In variousembodiments, the second component 60 can overlap a portion of the firstcomponent 50 such that the second component 60 is in contact with aportion of the body facing surface 72 of the first component 50. Invarious embodiments, the portion of the second component 60 in contactwith the portion of the body facing surface 72 of the first component 50can be bonded to each other such as, for example, by adhesive bonding,thermal bonding, ultrasonic bonding, etc. FIGS. 3, 4A, 4B, 8A, and 8Bprovide exemplary illustrations of embodiments in which the secondcomponent 60 overlaps a portion of the first component 50 so that thesecond component 60 is in contact with a portion of the body facingsurface 72 of the first component 50. In various embodiments, the secondcomponent 60 can underlap a portion of the first component 50 such thatthe second component 60 is in contact with a portion of the garmentfacing surface 74 of the first component 50. In various embodiments, theportion of the second component 60 in contact with the portion of thegarment facing surface 74 of the first component 50 can be bonded toeach other such as, for example, by adhesive bonding, thermal bonding,ultrasonic bonding, etc. FIGS. 5, 6A, 6B, 9A, and 9B, provide exemplaryillustrations of embodiments in which the second component 60 underlapsa portion of the first component 50 so that the second component 60 isin contact with a portion of the garment facing surface 74 of the firstcomponent 50.

FIGS. 3, 4A, and 4B provide an exemplary illustration of an absorbentarticle 10 having an exudate management layer 40 in fluid communicationwith the topsheet layer 30 of the absorbent article 10. In theembodiment illustrated in FIGS. 3, 4A, and 4B, the exudate managementlayer 40 is positioned on the body facing surface 32 of the topsheetlayer 30. The opening 42 of the exudate management layer 40 ispositioned such that the opening 42 is symmetrical about thelongitudinal centerline 18 but not symmetrical about the transversecenterline 80. The opening 42 of the exudate management layer 40illustrated in FIGS. 3, 4A, and 4B is positioned between the transversecenterline 80 and the posterior region 14 transverse direction end edge22. The transverse width of the first component 50 is uniform in thelongitudinal direction of the first component 50. The exudate managementlayer 40 is configured such that the second component 60 is in an atleast partially overlapping configuration with the first component 50such that a portion of the second component 60 is in contact with aportion of the body facing surface 72 of the first component 50. Theopening 42 of the exudate management layer 40 is generally circular inshape.

FIGS. 5, 6A, and 6B provide an exemplary illustration of an absorbentarticle 10 having an exudate management layer 40 in fluid communicationwith the topsheet layer 30 of the absorbent article 10. In theembodiment illustrated in FIGS. 5, 6A, and 6B, the exudate managementlayer 40 is positioned on the body facing surface 32 of the topsheetlayer 30. The opening 42 of the exudate management layer 40 ispositioned such that the opening 42 is symmetrical about thelongitudinal centerline 18 but not symmetrical about the transversecenterline 80. The opening 42 of the exudate management layer 40illustrated in FIGS. 5, 6A, and 6B, is positioned between the transversecenterline 80 and the posterior region 14 transverse direction end edge22. The transverse width of the first component 50 is uniform in thelongitudinal direction of the first component 50. The exudate managementlayer 40 is configured such that the second component 60 is in an atleast partially underlapping configuration with the first component 50such that a portion of the second component 60 is in contact with aportion of the garment facing surface 74 of the first component 50. Theopening 42 of the exudate management layer 40 is generally circular inshape.

FIG. 7 provides an exemplary illustration of an absorbent article 10having an exudate management layer 40 in fluid communication with thetopsheet layer 30 of the absorbent article 10. In the embodimentillustrated in FIG. 7 , the exudate management layer is positionedbetween the topsheet layer 30 and the absorbent core 38 of the absorbentarticle 10. The exudate management layer 40 can be in contact with thegarment facing surface 34 of the topsheet layer 30. The opening 42 ofthe exudate management layer 40 is positioned such that the opening 42is symmetrical about the longitudinal centerline 18 but not symmetricalabout the transverse centerline 80. The opening 42 of the exudatemanagement layer 40 is positioned between the transverse centerline 80and the posterior region 14 transverse direction end edge 22. Thetransverse width of the first component 50 is uniform in thelongitudinal direction of the first component 50. FIGS. 8A and 8Bprovide exemplary illustrations of an embodiment of an exudatemanagement layer 40 which can be present in the absorbent article 10 ofFIG. 7 . As illustrated in FIGS. 8A and 8B, the exudate management layeris configured such that the second component 60 is in an at leastpartially overlapping configuration with the first component 50 suchthat a portion of the second component 60 is in contact with a portionof the body facing surface 72 of the first component 50. The opening 42of the exudate management layer 40 is generally circular in shape. FIG.9A and 9B provide exemplary illustrations of an embodiment of an exudatemanagement layer 40 which can be present in the absorbent article 10 ofFIG. 7 . As illustrated in FIGS. 9A and 9B, the exudate management layeris configured such that the second component 60 is in an at leastpartially underlapping configuration with the first component 50 suchthat a portion of the second component 60 is in contact with a portionof the garment facing surface 74 of the first component 50. The opening42 of the exudate management layer 40 is generally circular in shape.

In various embodiments, the second component 60 can have a secondaryfold 68. The secondary fold 68 can be a fold within the second component60 and can bring a first portion 82 of the second component 60 intocontact with a second portion 84 of the second component 60. FIGS.16A-16D provide exemplary illustrations of cross-sectional side viewstaken in the longitudinal direction of exemplary exudate managementlayers 40 in which the second component 60 has a secondary fold 68. Theexudate management layer 40 illustrated in FIGS. 16A-16D has a firstcomponent 50 connected to a second component 60 via the primary fold 70and wherein the first component 50 and the second component 60 are in apartially overlapping configuration. Referring to FIG. 16A, the secondcomponent 60 is in an at least partially overlapping configuration withthe first component 50 such that the second component 60 is in contactwith a portion of the body facing surface 72 of the first component 50.The second component 60 further has a secondary fold 68 which brings afirst portion 82 of the second component 60 into contact with a secondportion 84 of the second component 60. The first portion 82 can be in anunderlapping configuration with the second portion 84 of the secondcomponent 60. Referring to FIG. 16B, the second component 60 is in an atleast partially overlapping configuration with the first component 50such that the second component 60 is in contact with a portion of thebody facing surface 72 of the first component 50. The second component60 further has a secondary fold 68 which brings a first portion 82 ofthe second component 60 into contact with a second portion 84 of thesecond component 60. The first portion 82 can be in an overlappingconfiguration with the second portion 84 of the second component 60.Referring to FIG. 16C, the second component 60 is in an at leastpartially underlapping configuration with the first component 50 suchthat the second component 60 is in contact with a portion of the garmentfacing surface 74 of the first component 50. The second component 60further has a secondary fold 68 which brings a first portion 82 of thesecond component 60 into contact with a second portion 84 of the secondcomponent 60. The first portion 82 can be in an overlappingconfiguration with the second portion 84 of the second component 60.Referring to FIG. 16D, the second component 60 is in an at leastpartially underlapping configuration with the first component 50 suchthat the second component 60 is in contact with a portion of the garmentfacing surface 74 of the first component 50. The second component 60further has a secondary fold 68 which brings a first portion 82 of thesecond component 60 into contact with a second portion 84 of the secondcomponent. While the embodiments illustrated in FIGS. 16A-16D illustratea single secondary fold 68 in the second components 60, it is to beunderstood that the second component 68 can have more than one secondaryfold 68. While the embodiments illustrated in FIGS. 16A-16D illustratethe secondary fold 68 of the second component 60 to be in a locationbeyond the second transverse direction end edge 54 of the firstcomponent 50, it is to be understood that the secondary fold 68 canoccur close in proximity to the second transverse direction end edge 54of the first component 50 or can occur such that the resultingoverlapping configuration of a first portion 82 and second portion 84 ofthe second component 60 can occur in an overlapping configuration withthe first component 50 of the exudate management layer 40.

Referring to FIG. 17 , in various embodiments, the second component 60of the exudate management layer 40 can have at least one opening 88which can be any suitable shape, such as, but not limited to, ovular,circular, rectangular, square, elliptical, hourglass, triangle, etc. Invarious embodiments, the shape of the opening 88 can include a shape ofa physical object, such as, for example, the outer shape of a leaf, ananimal, a star, a heart, a tear drop, a moon, or an abstractconfiguration. In various embodiments, the opening 88 can be elongateand can be oriented in the longitudinal direction (X) of the absorbentarticle 10. The opening 88 can be bounded by a perimeter 90 which canform an inner border or inner edge of the second component 60. Theopening 88 in the second component 60 can pass through the secondcomponent 60 from the body facing surface of the second component 60 tothe garment facing surface of the second component 60. In the event ofbody exudate coming into the location of the opening 88 in the secondcomponent, the opening 88 can form a cup or well-like structure forholding body exudate and preventing its leakage away from a region ofthe absorbent article 10 and towards the edges of the absorbent article10. The opening 88 can be located at various positions of the secondcomponent 60. In various embodiments, the second component 60 can havemore than one opening 88 and the plurality of openings 88 can bearranged in the second component 60 in any manner deemed suitable. Invarious embodiments, the opening 88 can be formed by cutting, punching,or otherwise separating a first portion of the material forming thesecond component 60 from a second portion of material forming the secondcomponent 60. The second portion of material forming the secondcomponent 60 is that portion of material which remains as the secondcomponent 60 of the exudate management layer 40 and is connected to thefirst component 50 via the primary fold 70. In various embodiments, thefirst portion of the material which has been cut, punched, or otherwiseseparated from the second portion of material forming the secondcomponent 60 can be discarded. In various embodiments, the first portionof the material which has been cut, punched, or otherwise separated fromthe second portion of material forming the second component 60 can bebonded to the absorbent core 38 and can form projection(s) 86 extendingupward, in the depth direction (Z) from the body facing surface of theabsorbent core 38. The material forming the projection(s) 86 can bebonded to the absorbent core 38 prior to or after the cutting, punching,or otherwise separating the first portion of material forming the secondcomponent 60 from the second portion of material forming the secondcomponent 60.

Referring to FIG. 18 , in various embodiments, the absorbent core 38 canhave at least one opening 94 which can be any suitable shape, such as,but not limited to, ovular, circular, rectangular, square, elliptical,hourglass, triangle, etc. In various embodiments, the shape of theopening 94 can include a shape of a physical object, such as, forexample, the outer shape of a leaf, an animal, a star, a heart, a teardrop, a moon, or an abstract configuration. In various embodiments, theopening 94 can be elongate and can be oriented in the longitudinaldirection (X) of the absorbent article 10. The opening 94 can be boundedby a perimeter 96 which can form an inner border or inner edge of theabsorbent core 38. The opening 94 in the absorbent core 38 passesthrough the absorbent core 38 from the body facing surface of theabsorbent core 38 to the garment facing surface of the absorbent core38. In the event of body exudate coming into the location of the opening94 in the absorbent core 38, the opening 94 can form a cup or well-likestructure for holding the body exudate and preventing its leakage awayfrom a region of the absorbent article 10 and towards the edges of theabsorbent article 10. The opening 94 can be located at various positionsof the absorbent core 38 and within the region of the absorbent core 38visible through the opening 42 of the exudate management layer 40. Invarious embodiments, the absorbent core 38 can have more than oneopening 94 and the plurality of openings 94 can be arranged in theabsorbent core 38 in any manner deemed suitable. The opening 94 in theabsorbent core 38 can be formed by cutting, punching, or otherwiseseparating a first portion of material forming the absorbent core 38from a second portion of material forming the absorbent core 38. Thesecond portion of material forming the absorbent core 38 is that portionof material which remains as the absorbent core 38 of the absorbentarticle 10. In various embodiments, the first portion of the materialwhich has been cut, punched, or otherwise separated from the secondportion of material forming the absorbent core 38 can be discarded. Invarious embodiments, the first portion of the material which has beencut, punched, or otherwise separated from the second portion of materialforming the absorbent core 38 can be bonded to the second component 60of the exudate management layer 40 and can form projection(s) 92extending upward, in the depth direction (Z) from the body facingsurface of the second component 60. The material forming theprojection(s) 92 can be bonded to the second component 60 prior to orafter the cutting, punching, or otherwise separating of the secondcomponent 60 from the first component 50 of the exudate management layer40.

As described herein, the exudate management layer 40 has a firstcomponent 50 which at least partially defines an opening 42 and a secondcomponent 60 connected to the first component 50 via a primary fold 70.In various embodiments, the exudate management layer 40 can have a thirdcomponent connected to the first component 50 via a third componentprimary fold. In various embodiments, the exudate management layer 40can have a third component and a fourth component wherein each of thethird component and fourth component is connected to the first component50 via their own component primary folds. In various embodiments, theexudate management layer 40 can have a third component, a fourthcomponent, and a fifth component connected to the first component 50 viatheir own component primary folds. Referring to FIG. 19 , FIG. 19provides an exemplary illustration of an exudate management layer 40having a first component 50, a second component 60 connected to thefirst component 50 via primary fold 70, a third component 130 connectedto the first component 50 via third component primary fold 132, and anopening 42 defined by the first component 50, the primary fold 70, andthe third component primary fold 132. The second component 60 can extendfrom the primary fold 70 in the longitudinal direction (X) of theabsorbent article 10 in a direction towards the posterior region 14 ofthe absorbent article 10 and the third component 130 can extend from thethird component primary fold 132 in the longitudinal direction (X) ofthe absorbent article 10 in a direction towards the anterior region 12of the absorbent article 10. FIG. 20 provides an exemplary illustrationof an exudate management layer 40 having a first component 50, a secondcomponent 60 connected to the first component 50 via primary fold 70, athird component 142 connected to the first component via third componentprimary fold 144, a fourth component 146 connected to the firstcomponent 50 via fourth component primary fold 148, and an opening 42defined by the first component 50, the primary fold 70, the thirdcomponent primary fold 144, and the fourth component primary fold 148.In the embodiments illustrated in FIG. 20 , the second component 60 canextend from the primary fold 70 in the longitudinal direction (X) of theabsorbent article 10 in a direction towards the posterior region 14 ofthe absorbent article 10, the third component 142 can extend from thethird component primary fold 144 in the transverse direction (Y) of theabsorbent article 10, and the fourth component 146 can extend from thefourth component primary fold 148 in the transverse direction (Y) of theabsorbent article 10. FIG. 21 provides an exemplary illustration of anexudate management layer 40 having a first component 50, a secondcomponent 60 connected to the first component 50 via primary fold 70, athird component 130 connected to the first component 50 via thirdcomponent primary fold 132, a fourth component 134 connected to thefirst component 50 via fourth component primary fold 136, a fifthcomponent 138 connected to the first component 50 via fifth componentprimary fold 140, and an opening 42 defined by the first component 50,the primary fold 70, the third component primary fold 132, the fourthcomponent primary fold 136, and the fifth component primary fold 140. Inthe embodiment illustrated in FIG. 21 , the second component 60 canextend from the primary fold 70 in the longitudinal direction (X) of theabsorbent article 10 in a direction towards the posterior region 14 ofthe absorbent article 10, the third component 130 can extend from thethird component primary fold 132 in the longitudinal direction (X) ofthe absorbent article 10 in a direction towards the anterior region 12of the absorbent article 10, the fourth component 134 can extend fromthe fourth component primary fold 136 in the transverse direction (Y) ofthe absorbent article 10, and the fifth component 138 can extend fromthe fifth component primary fold 140 in the transverse direction (Y) ofthe absorbent article 10.

In various embodiments, such as, for example illustrated in FIG. 22 ,the exudate management layer 40 can have at least two openings 42 forthe capture and containment of fecal material. In various embodiments,the exudate management layer 40 can have at least 1, 2, 3, 4, or 5openings 42. Each of the openings 42 can have any shape deemed suitablesuch as, for example, described herein. Each of the openings 42 can bebounded at least partially by a perimeter 44 and at least partially by aprimary fold 70 of their respective second component 60. The pluralityof openings 42 can be arranged in the exudate management layer 40 in anymanner deemed suitable. In various embodiments, at least one of theplurality of openings 42 can be symmetrical about the longitudinalcenterline 18. In various embodiments, none of the openings 42 issymmetrical about the longitudinal centerline 18. In variousembodiments, one of the plurality of openings 42 can be positioned thatthat a portion of the opening 42 crosses over the transverse centerline80. In various embodiments, each of the openings 42 is positionedbetween the transverse centerline 80 and the second transverse directionend edge 22 of the absorbent article 10.

Containment Flaps:

In various embodiments, the absorbent article can have containmentflaps. FIGS. 2, 3, 5, and 7 provide illustrations of exemplaryembodiments of an absorbent article 10 with containment flaps, 210 and212. In various embodiments, containment flaps, 210 and 212, can besecured to the topsheet layer 30 of the absorbent article 10 in agenerally parallel, spaced relation with each other laterally inward ofthe longitudinal direction side edges 24 to provide a barrier againstthe flow of body exudates in the transverse direction (Y) of theabsorbent article 10. In various embodiments, the containment flaps, 210and 212, can extend longitudinally from the anterior region 12 of theabsorbent article 10, through the central region 16 to the posteriorregion 14 of the absorbent article 10.

The containment flaps, 210 and 212, can be constructed of a fibrousmaterial which can be similar to the material forming the topsheet layer30. Other conventional material, such as polymer films, can also beemployed. Each containment flap, 210 and 212, can have a moveable distalend 214 which can include flap elastics 216. Suitable elastic materialsfor the flap elastics 216 can include sheets, strands or ribbons ofnatural rubber, synthetic rubber, or thermoplastic elastomericmaterials. In various embodiments, the flap elastics 216 can have twostrands of elastomeric material extending longitudinally along thedistal ends 214 of the containment flaps, 210 and 212, in generallyparallel, spaced relation with each other. The elastic strands can bewithin the containment flaps, 210 and 212, while in an elasticallycontractible condition such that contraction of the strands gathers andshortens the distal ends 214 of the containment flaps, 210 and 212. As aresult, the elastic strands can bias the distal ends 214 of eachcontainment flap, 210 and 212, toward a position spaced from theproximal end of the containment flaps, 210 and 212, so that thecontainment flaps, 210 and 212, can extend away from the topsheet layer30 in a generally upright orientation of the containment flaps, 210 and212, especially in the central region 16 of the absorbent article 10,when the absorbent article 10 is fitted on the wearer. The distal end214 of the containment flaps, 210 and 212, can be connected to the flapelastics 216 by partially doubling the containment flap, 210 and 212,material back upon itself by an amount which can be sufficient toenclose the flap elastics 216. It is to be understood, however, that thecontainment flaps, 210 and 212, can have any number of strands ofelastomeric material and may also be omitted from the absorbent article10 without departing from the scope of this disclosure.

In various embodiments, such as, for example, illustrated in FIGS. 3,4A, 4B, 5, 6A, and 6B, the absorbent article 10 can have an exudatemanagement layer 40 positioned on the body facing surface 32 of thetopsheet layer 30. In various embodiments, the exudate management layer40 can be sized and positioned such that the longitudinal direction sideedges 56 of the first component 50 of the exudate management layer 40are located underneath the containment flaps, 210 and 212, of theabsorbent article 10. In various embodiments, portions of the firstcomponent 50 such as, for example, at least portions of the longitudinaldirection side edges 56, can be bonded to the containment flaps, 210 and212. In such embodiments, when the containment flaps, 210 and 212,extend away from the topsheet layer 30 in a generally uprightorientation of the containment flaps, 210 and 212, the exudatemanagement layer 40 can be elevated away from the topsheet layer 30 andprovide a close to body fit of the absorbent article 10 to the body ofthe wearer. In various embodiments, the transverse direction end edges,52 ad 54, of the first component 50 can be bonded to the topsheet layer30 so as to create a pocket for the body exudate when the exudatemanagement layer 40 is elevated away from the topsheet layer 30 as thecontainment flaps, 210 and 212, are in a generally upright orientationduring usage of the absorbent article 10.

Acquisition Layer:

In various embodiments, the absorbent article 10 can have an acquisitionlayer. The acquisition layer can help decelerate and diffuse surges orgushes of liquid body exudates penetrating the topsheet layer 30. Invarious embodiments, the exudate management layer 40 can be positionedon the body facing surface 32 of the topsheet layer 30 and theacquisition layer can be positioned between the topsheet layer 30 andthe absorbent core 38. In various embodiments, the acquisition layer canbe positioned on the body facing surface 32 of the topsheet layer 30 andthe exudate management layer 40 can be positioned on the body facingsurface of the acquisition layer. In various embodiments, an absorbentarticle 10 can have an exudate management layer 40 positioned betweenthe topsheet layer 30 and the absorbent core 38 with an acquisitionlayer positioned between the exudate management layer 40 and theabsorbent core 38.

The acquisition layer may have any longitudinal length dimension asdeemed suitable. In various embodiments, the longitudinal length of theacquisition layer can be the same as the longitudinal length of theabsorbent core 38. In various embodiments, the longitudinal length ofthe acquisition layer can be shorter than the longitudinal length of theabsorbent core 38. In such embodiments, the acquisition layer may bepositioned at any desired location along the longitudinal length of theabsorbent core 38.

In an embodiment, the acquisition layer can include natural fibers,synthetic fibers, superabsorbent material, woven material, nonwovenmaterial, wet-laid fibrous webs, a substantially unbounded airlaidfibrous web, an operatively bonded, stabilized-airlaid fibrous web, orthe like, as well as combinations thereof. In an embodiment, theacquisition layer can be formed from a material that is substantiallyhydrophobic, such as a nonwoven web composed of polypropylene,polyethylene, polyester, and the like, and combinations thereof. Invarious embodiments, the acquisition layer can include conjugate,biconstituent, and/or homopolymer fibers of staple or other lengths andmixtures of such fibers with other types of fibers. In variousembodiments, the acquisition layer can have fibers which can have adenier of greater than about 5. In various embodiments, the acquisitionlayer can have fibers which can have a denier of less than about 5.

In various embodiments, the acquisition layer can be a bonded carded webor an airlaid web. In various embodiments, the bonded carded web may be,for example, a powder bonded carded web, an infrared bonded carded web,or a through air bonded carded web.

In various embodiments, the basis weight of the acquisition layer can beat least about 10 or 20 gsm. In various embodiments, the basis weight ofthe acquisition layer can be from about 10, 20, 30, 40, 50 or 60 gsm toabout 65, 70, 75, 80, 85, 90, 100, 110, 120, or 130 gsm. In variousembodiments, the basis weight of the acquisition layer can be less thanabout 130, 120, 110, 100, 90, 85, 80, 75, 70, 65, 60 or 50 gsm.

Side Panels:

FIG. 23 provides an illustration of an exemplary embodiment of aperspective view of an absorbent article 10 such as a pant, such as, forexample, a training pant, youth pant, diaper pant, or an adultincontinence pant. In an embodiment in which the absorbent article 10can be a training pant, youth pant, diaper pant, or adult incontinencepant, the absorbent article 10 may have front side panels, 260 and 262,and rear side panels, 264 and 266. FIG. 23 provides a non-limitingillustration of an absorbent article 10 that can have side panels, suchas front side panels, 260 and 262, and rear side panels, 264 and 266.The front side panels 260 and 262 and the rear side panels 264 and 266of the absorbent article 10 can be bonded to the absorbent article 10 inthe respective anterior and posterior regions, 12 and 14, and can extendoutwardly beyond the longitudinal side edges 24 of the absorbent article10. In an example, the front side panels, 260 and 262, can be bonded tothe liquid impermeable layer 36 such as being bonded thereto byadhesive, by pressure bonding, by thermal bonding or by ultrasonicbonding. The back side panels, 264 and 266, may be secured to the liquidimpermeable layer 36 in substantially the same manner as the front sidepanels, 260 and 262. Alternatively, the front side panels, 260 and 262,and the back side panels, 264 and 266, may be formed integrally with theabsorbent article 10, such as by being formed integrally with the liquidimpermeable layer 36, the topsheet layer 30 or other layers of theabsorbent article 10.

For improved fit and appearance, the front side panels, 260 and 262, andthe back side panels, 264 and 266, can suitably have an average lengthmeasured parallel to the longitudinal centerline 18 of the absorbentarticle 10 that is about 20 percent or greater, and more suitably about25 percent or greater, of the overall length of the absorbent article10, also measured parallel to the longitudinal centerline 18. Forexample, absorbent articles 10 having an overall length of about 54centimeters, the front side panels, 260 and 262, and the back sidepanels, 264 and 266, suitably have an average length of about 10centimeters or greater, and more suitably have an average length ofabout 15 centimeters. Each of the front side panels, 260 and 262, andback side panels, 264 and 266, can be constructed of one or moreindividual, distinct pieces of material. For example, each front sidepanel, 260 and 262, and back side panel, 264 and 266, can include firstand second side panel portions (not shown) joined at a seam (not shown),with at least one of the portions including an elastomeric material.Alternatively, each individual front side panel, 260 and 262, and backside panel, 264 and 266, can be constructed of a single piece ofmaterial folded over upon itself along an intermediate fold line (notshown).

The front side panels, 260 and 262, and back side panels, 264 and 266,can each have an outer edge 270 spaced laterally from the engagementseam 272, a leg end edge 274 disposed toward the longitudinal center ofthe absorbent article 10, and a waist end edge 276 disposed toward alongitudinal end of the absorbent article 10. The leg end edge 274 andwaist end edge 276 can extend from the longitudinal side edges 24 of theabsorbent article 10 to the outer edges 270. The leg end edges 274 ofthe front side panels, 260 and 262, and back side panels, 264 and 266,can form part of the longitudinal side edges 24 of the absorbent article10. The leg end edges 274 of the illustrated absorbent article 10 can becurved and/or angled relative to the transverse centerline 80 to providea better fit around the wearer's legs. However, it is understood thatonly one of the leg end edges 274 can be curved or angled, such as theleg end edge 274 of the posterior region 14, or neither of the leg endedges 274 can be curved or angled, without departing from the scope ofthis disclosure. The waist end edges 276 can be parallel to thetransverse centerline 80. The waist end edges 276 of the front sidepanels, 260 and 262, can form part of the first transverse direction endedge 20 of the absorbent article 10, and the waist end edges 276 of theback side panels, 264 and 266, can form part of the second transversedirection end edge 22 of the absorbent article 10.

The front side panels, 260 and 262, and back side panels, 264 and 266,can include an elastic material capable of stretching laterally.Suitable elastic materials, as well as one described process forincorporating elastic front side panels, 260 and 262, and back sidepanels, 264 and 266, into an absorbent article 10 are described in thefollowing U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel etal., U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola, U.S. Pat.No. 5,104,116 issued Apr. 14, 1992 to Pohjola, and U.S. Pat. No.5,046,272 issued Sep. 10, 1991 to Vogt et al.; all of which areincorporated herein by reference. As an example, suitable elasticmaterials include a stretch-thermal laminate (STL), a neck-bondedlaminate (NBL), a reversibly necked laminate, or a stretch-bondedlaminate (SBL) material. Methods of making such materials are well knownto those skilled in the art and described in U.S. Pat. No. 4,663,220issued May 5, 1987 to Wisneski et al., U.S. Pat. No. 5,226,992 issuedJul. 13, 1993 to Morman, and European Patent Application No. EP 0 217032 published on Apr. 8, 1987, in the names of Taylor et al., and PCTApplication WO 01/88245 in the name of Welch et al., all of which areincorporated herein by reference. Other suitable materials are describedin U.S. patent application Ser. Nos. 12/649,508 to Welch et al. and12/023,447 to Lake et al., all of which are incorporated herein byreference. Alternatively, the front side panels, 260 and 262, and backside panels, 264 and 266, may include other woven or non-wovenmaterials, such as those described above as being suitable for theliquid impermeable layer 36.

Method to Determine Percent Open Area:

The percentage of open area can be determined by using the imageanalysis measurement method described herein. In this context, the openarea is considered the regions within a material where light transmittedfrom a light source passes directly thru those regions unhindered in thematerial of interest. Generally, the image analysis method determines anumeric value of percent open area for a material via specific imageanalysis measurement parameters such as area. The percent open areamethod is performed using conventional optical image analysis techniquesto detect open area regions in both land areas and projectionsseparately and then calculating their percentages in each. To separateland areas and projections for subsequent detection and measurement,incident lighting is used along with image processing steps. An imageanalysis system, controlled by an algorithm, performs detection, imageprocessing and measurement and also transmits data digitally to aspreadsheet database. The resulting measurement data are used todetermine the percent open area of materials possessing land areas andprojections.

The method for determining the percent open area in both land areas andprojections of a given material includes the step of acquiring twoseparate digital images of the material. An exemplary setup foracquiring the image is representatively illustrated in FIG. 24 .Specifically, a CCD video camera 300 (e.g., a Leica DFC 310 FX videocamera operated in gray scale mode and available from Leica Microsystemsof Heerbrugg, Switzerland) is mounted on a standard support 302 such asa Polaroid MP-4 Land Camera standard support or equivalent availablefrom Polaroid Resource Center in Cambridge, Miss. The standard support302 is attached to a macro-viewer 304 such as a KREONITE macro-vieweravailable from Dunning Photo Equipment, Inc., having an office in Bixby,Okla. An auto stage 308 is placed on the upper surface 306 of themacro-viewer 304. The auto stage 308 is used to automatically move theposition of a given material for viewing by the camera 300. A suitableauto stage is Model H112, available from Prior Scientific Inc., havingan office in Rockland, Mass.

The material possessing land areas and projections is placed on the autostage 308 under the optical axis of a 60 mm Nikon AF Micro Nikkor lens310 with an f-stop setting of 4. The Nikon lens 310 is attached to theLeica DFC 310 FX camera 300 using a c-mount adaptor. The distance D1from the front face 312 of the Nikon lens 310 to the material is 21 cm.The material is laid flat on the auto stage 308 and any wrinkles removedby gentle stretching and/or fastening it to the auto stage 308 surfaceusing transparent adhesive tape at its outer edges. The material isoriented so the machine-direction (MD) runs in the horizontal directionof the resulting image. The material surface is illuminated withincident fluorescent lighting provided by a 16 inch diameter, 40 watt,GE Circline fluorescent lamp 314. The lamp 314 is contained in a fixturethat is positioned so it is centered over the material and under thevideo camera above and is a distance D2 of 3 inches above the materialsurface. The illumination level of the lamp 314 is controlled with aVariable Auto-transformer, type 3PN1010, available from Staco EnergyProducts Co. having an office in Dayton, Ohio. Transmitted light is alsoprovided to the material from beneath the auto stage 308 by a bank offive 20 watt fluorescent lights 316 covered with a diffusing plate 318.The diffusing plate 318 is inset into, and forms a portion of, the uppersurface 306 of the macro-viewer 304. The diffusing plate 318 is overlaidwith a black mask 320 possessing a 3-inch by 3-inch opening 322. Theopening 322 is positioned so that it is centered under the optical axisof the Leica camera and lens system. The distance D3 from the opening322 to the surface of the auto stage 308 is approximately 17 cm. Theillumination level of the fluorescent light bank 316 is also controlledwith a separate Variable Auto-transformer.

The image analysis software platform used to perform the percent openarea measurements is a QWIN Pro (Version 3.5.1) available from LeicaMicrosystems, having an office in Heerbrugg, Switzerland. The system andimages are also calibrated using the QWIN software and a standard rulerwith metric markings at least as small as one millimeter. Thecalibration is performed in the horizontal dimension of the video cameraimage. Units of millimeters per pixel are used for the calibration.

The method for determining the percent open area of a given materialincludes the step of performing several area measurements from bothincident and transmitted light images. Specifically, an image analysisalgorithm is used to acquire and process images as well as performmeasurements using Quantimet User Interactive Programming System (QUIPS)language. The image analysis algorithm is reproduced below.

NAME = % Open Area − Land vs Projection Regions−1 PURPOSE = Measures %open area on ‘land’ and ‘projection’ regions via ‘sandwich’ lightingtechnique DEFINE VARIABLES & OPEN FILES  Open File ( C:\Data\39291\%Open Area\data.xls, channel #1 )  MFLDIMAGE = 2  TOTCOUNT = 0  TOTFIELDS= 0  SAMPLE ID AND SET UP  Configure ( Image Store 1392 × 1040, GreyImages 81, Binaries 24 )  Enter Results Header  File Results Header (channel #1 )  File Line ( channel #1 )  Image Setup DC Twain [PAUSE] (Camera 1, AutoExposure Off, Gain 0.00,  ExposureTime 34.23 msec,Brightness 0, Lamp 38.83 )  Measure frame ( x 31, y 61, Width 1330,Height 978 )  Image frame ( x 0, y 0, Width 1392, Height 1040 )  --Calvalue = 0.0231 mm/px  CALVALUE = 0.0231  Calibrate ( CALVALUECALUNITS$ per pixel )  Clear Accepts  For ( SAMPLE = 1 to 1, step 1 )Clear Accepts File ( “Field No.”, channel #1, field width: 9, leftjustified ) File ( “Land Area”, channel #1, field width: 9, leftjustified ) File ( “Land Open Area”, channel #1, field width: 13, leftjustified ) File ( “%Open Land Area”, channel #1, field width: 15, leftjustified ) File ( “Proj. Area”, channel #1, field width: 9, leftjustified ) File ( “Proj. Open Area”, channel #1, field width: 13, leftjustified ) File ( “% Open Proj. Area”, channel #1, field width: 15,left justified ) File ( “Total % Open Area”, channel #1, field width:14, left justified ) File Line ( channel #1 ) Stage ( Define Origin )Stage ( Scan Pattern, 5 × 1 fields, size 82500.000000 × 82500.000000 )IMAGE ACQUISITION I - Projection isolation For ( FIELD = 1 to 5, step 1)  Display ( Image0 (on), frames (on,on), planes(off,off,off,off,off,off), lut 0, x 0, y 0, z  1, Reduction off ) PauseText ( “Ensure incident lighting is correct (WL = 0.88 − 0.94) andacquire image.” )  Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposureOff, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 ) Acquire ( into Image0 )  DETECT - Projections only  PauseText ( “Ensurethat threshold is set at least to the right of the left gray-levelhistogram peak which corresponds to the ‘land’ region.” )  Detect[PAUSE] ( whiter than 127, from Image0 into Binary0 delineated ) BINARYIMAGE PROCESSING Binary Amend (Close from Binary0 to Binary1, cycles 10,operator Disc, edge erode on) Binary Identify ( Fill Holes from Binary1to Binary1 ) Binary Amend (Open from Binary1 to Binary2, cycles 20,operator Disc, edge erode on) Binary Amend (Close from Binary2 toBinary3, cycles 8, operator Disc, edge erode on ) PauseText (“Toggle<control> and <b> keys to check bump detection and correct if necessary.” )  Binary Edit [PAUSE] ( Draw from Binary3 to Binary3, nibFill, width 2 )  Binary Logical ( copy Binary3, inverted to Binary4 )IMAGE ACQUISITION 2 - % Open Area Display ( Image0 (on), frames (on,on),planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1, Reduction off )PauseText ( “Turn off incident light & ensure transmitted lighting iscorrect (WL =  0.97) and acquire image.” )  Image Setup DC Twain [PAUSE]( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec,Brightness 0, Lamp 38.83 )  Acquire ( into Image0 )  DETECT - Open areasonly  Detect ( whiter than 210, from Image0 into Binary10 delineated ) BINARY IMAGE PROCESSING  Binary Logical ( C = A AND B : C Binary11, ABinary3, B Binary10 )  Binary Logical ( C = A AND B : C Binary12, ABinary4, B Binary10 )  MEASURE AREAS - Land, projections, open areawithin each  -- Land Area  MFLDIMAGE = 4  Measure field ( planeMFLDIMAGE, into FLDRESULTS(1), statistics into  FLDSTATS(7,1) ) Selectedparameters: Area  LANDAREA = FLDRESULTS(1)  -- Projection Area MFLDIMAGE = 3  Measure field ( plane MFLDIMAGE, into FLDRESULTS(1),statistics into  FLDSTATS(7,1) ) Selected parameters: Area  BUMPAREA =FLDRESULTS(1)  -- Open Projection area  MFLDIMAGE = 11  Measure field (plane MFLDIMAGE, into FLDRESULTS(1), statistics into  FLDSTATS(7,1) )Selected parameters: Area  APBUMPAREA = FLDRESULTS(1)  -- Open land area MFLDIMAGE = 12  Measure field ( plane MFLDIMAGE, into FLDRESULTS(1),statistics into  FLDSTATS(7,1) ) Selected parameters: Area  APLANDAREA =FLDRESULTS(1)  -- Total % open area  MFLDIMAGE = 10  Measure field (plane MFLDIMAGE, into FLDRESULTS(1), statistics into  FLDSTATS(7,1) )Selected parameters: Area %  TOTPERCAPAREA = FLDRESULTS(1)  CALCULATEAND OUTPUT AREAS  PERCAPLANDAREA = APLANDAREA/LANDAREA*100 PERCAPBUMPAREA = APBUMPAREA/BUMPAREA*100  File ( FIELD, channel #1, 0digits after ‘.’ )  File ( LANDAREA, channel #1, 2 digits after ‘.’ ) File ( APLANDAREA, channel #1, 2 digits after ‘.’ )  File (PERCAPLANDAREA, channel #1, 1 digit after ‘.’ )  File ( BUMPAREA,channel #1, 2 digits after ‘.’ )  File ( APBUMPAREA, channel #1, 4digits after ‘.’ )  File ( PERCAPBUMPAREA, channel #1, 5 digits after‘.’ )  File ( TOTPERCAPAREA, channel #1, 2 digits after ‘.’ )  File Line( channel #1 )  Stage ( Step, Wait until stopped + 1100 msecs ) Next(FIELD) PauseText ( “If no more samples, enter ‘0.’” ) Input ( FINISH )If ( FINISH=0 )  Goto OUTPUT Endif PauseText ( “Place the next replicatespecimen on the auto-stage, turn on incident light  and turn-off and/orblock sub-stage lighting.” ) Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00,  ExposureTime 34.23 msec, Brightness 0,Lamp 38.83 ) File Line (channel #1)  Next ( SAMPLE )  OUTPUT:  CloseFile ( channel #1 ) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the material set informationwhich is sent to the EXCEL file.

The analyst is next prompted by a live image set up window on thecomputer monitor screen to place a material onto the auto-stage 308. Thematerial should be laid flat and gentle force applied at its edges toremove any macro-wrinkles that may be present. It should also be alignedso that the machine direction runs horizontally in the image. At thistime, the Circline fluorescent lamp 314 can be on to assist inpositioning the material. Next, the analyst is prompted to adjust theincident Circline fluorescent lamp 314 via the Variable Auto-transformerto a white level reading of approximately 0.9. The sub-stage transmittedlight bank 316 should either be turned off at this time or masked usinga piece of light-blocking, black construction paper placed over the 3inch by 3 inch opening 322.

The analyst is now prompted to ensure that the detection threshold isset to the proper level for detection of the projections using theDetection window which is displayed on the computer monitor screen.Typically, the threshold is set using the white mode at a pointapproximately near the middle of the 8-bit gray-level range (e.g. 127).If necessary, the threshold level can be adjusted up or down so that theresulting detected binary will optimally encompass the projections shownin the acquired image with respect to their boundaries with thesurrounding land region.

After the algorithm automatically performs several binary imageprocessing steps on the detected binary of the projections, the analystwill be given an opportunity to re-check projection detection andcorrect any inaccuracies. The analyst can toggle both the ‘control’ and‘b’ keys simultaneously to re-check projection detection against theunderlying acquired gray-scale image. If necessary, the analyst canselect from a set of binary editing tools (e.g. draw, reject, etc.) tomake any minor adjustments. If care is taken to ensure properillumination and detection in the previously described steps, little orno correction at this point should be necessary.

Next, the analyst is prompted to turn off the incident Circlinefluorescent lamp 314 and either turn on the sub-stage transmitted lightbank or remove the light blocking mask. The sub-stage transmitted lightbank is adjusted by the Variable Auto-transformer to a white levelreading of approximately 0.97. At this point, the image focus can beoptimized for the land areas of the material.

The algorithm, after performing additional operations on the resultingseparate binary images for projections, land areas and open area, willthen automatically perform measurements and output the data into adesignated EXCEL spreadsheet file. The following measurement parameterdata will be located in the EXCEL file after measurements and datatransfer has occurred:

Land Area

Land Open Area

Land % Open Area

Projection Area

Projection Open Area

Projection % Open Area

Total % Open Area

Following the transfer of data, the algorithm will direct the auto-stage308 to move to the next field-of-view and the process of turning on theincident, Circline fluorescent lamp 314 and blocking the transmittedsub-stage lighting bank 316 will begin again. This process will repeatfour times so that there will be five sets of data from five separatefield-of-view images per single material replicate.

Multiple sampling replicates from a single material can be performedduring a single execution of the QUIPS algorithm (Note: The SampleFor-Next line in the algorithm needs to be adjusted to reflect thenumber of material replicate analyses to be performed per material). Thefinal material mean spread value is usually based on an N=5 analysisfrom five, separate, material subsample replicates. A comparison betweendifferent materials can be performed using a Student's T analysis at the90% confidence level.

Method to Determine Height of Projections Test Method:

The height of the projections can be determined by using the imageanalysis measurement method described herein. The image analysis methoddetermines a dimensional numeric height value for projections usingspecific image analysis measurements of both land areas and projectionswith underlying land regions in a sample and then calculating theprojection height alone by difference between the two. The projectionheight method is performed using conventional optical image analysistechniques to detect cross-sectional regions of both land areas andprojection structures and then measure a mean linear height value foreach when viewed using a camera with incident lighting. The resultingmeasurement data are used to compare the projection heightcharacteristics of different types of body-side intake layers.

Prior to performing image analysis measurements, the sample of interestmust be prepared in such a way to allow visualization of arepresentative cross-section that passes thru the center of aprojection. Cross-sectioning can be performed by anchoring arepresentative piece of the sample on at least one of its cross-machinerunning straight edges on a flat, smooth surface with a strip of tapesuch as ¾ inch SCOTCH® Magic™ tape produced by 3M. Cross-sectioning isthen performed by using a new, previously unused single edge carbonsteel blue blade (PAL) and carefully cutting in a direction away fromand orthogonal to the anchored edge and thru the centers of at least oneprojection and preferably more if projections are arranged in rowsrunning in the machine direction. Any remaining rows of projectionslocated behind the cross-sectioned face of projections should be cutaway and removed prior to mounting so that only cross-sectionedprojections of interest are present. Such blades for cross-sectioningcan be acquired from Electron Microscopy Sciences of Hatfield, Pa. (Cat.#71974). Cross-sectioning is performed in the machine-direction of thesample, and a fresh, previously unused blade should be used for each newcross-sectional cut. The cross-sectioned face can now be mounted so thatthe projections are directed upward away from the base mount using anadherent such as two-side tape so that it can be viewed using a videocamera possessing an optical lens. The mount itself and any backgroundbehind the sample that will be viewed by the camera must be darkenedusing non-reflective black tape and black construction paper 346 (shownin FIG. 25 ), respectively. For a typical sample, enough cross-sectionsshould be cut and mounted separately from which a total of sixprojection height values can be determined.

An exemplary setup for acquiring the images is representativelyillustrated in FIG. 25 . Specifically, a CCD video camera 330 (e.g., aLeica DFC 310 FX video camera operated in gray scale mode is availablefrom Leica Microsystems of Heerbrugg, Switzerland) is mounted on astandard support 332 such as a Polaroid MP-4 Land Camera standardsupport available from Polaroid Resource Center in Cambridge, Miss. orequivalent. The standard support 332 is attached to a macro-viewer 334such as a KREONITE macro-viewer available from Dunning Photo Equipment,Inc., having an office in Bixby, Okla. An auto stage 336 is placed onthe upper surface of the macro-viewer 334. The auto stage 336 is used tomove the position of a given sample for viewing by the camera 330. Asuitable auto stage 336 is a Model H112, available from Prior ScientificInc., having an office in Rockland, Mass.

The darkened sample mount 338 exposing the cross-sectioned sample facepossessing land areas and projections is placed on the auto stage 336under the optical axis of a 50 mm Nikon lens 340 with an f-stop settingof 2.8. The Nikon lens 340 is attached to the Leica DFC 310 FX camera330 using a 30 mm extension tube 342 and a c-mount adaptor. The samplemount 338 is oriented so the sample cross-section faces flush toward thecamera 330 and runs in the horizontal direction of the resulting imagewith the projections directed upward away from the base mount. Thecross-sectional face is illuminated with incident, incandescent lighting344 provided by two, 150 watt, GE Reflector Flood lamps. The two floodlamps are positioned so that they provide more illumination to thecross-sectional face than to the sample mount 338 beneath it in theimage. When viewed from overhead directly above the camera 330 andunderlying sample cross-section mount 338, the flood lamps 344 will bepositioned at approximately 30 degrees and 150 degrees with respect tothe horizontal plane running thru the camera 330. From this view thecamera support will be at the 90 degree position. The illumination levelof the lamps is controlled with a Variable Auto-transformer, type3PN1010, available from Staco Energy Products Co. having an office inDayton, Ohio.

The image analysis software platform used to perform measurements is aQWIN Pro (Version 3.5.1) available from Leica Microsystems, having anoffice in Heerbrugg, Switzerland. The system and images are alsocalibrated using the QWIN software and a standard ruler with metricmarkings at least as small as one millimeter. The calibration isperformed in the horizontal dimension of the video camera image. Unitsof millimeters per pixel are used for the calibration.

Thus, the method for determining projection heights of a given sampleincludes the step of performing several, dimensional measurements.Specifically, an image analysis algorithm is used to acquire and processimages as well as perform measurements using Quantimet User InteractiveProgramming System (QUIPS) language. The image analysis algorithm isreproduced below.

NAME = Height − Projection vs Land Regions − 1 PURPOSE = Measures heightof projection and land regions DEFINE VARIABLES & OPEN FILES  -- Thefollowing line is set to designate where measurement data will bestored. Open File (C:\Data\39291\Height\data.xls, channel #1) FIELDS = 6SAMPLE ID AND SET UP Enter Results Header File Results Header ( channel#1 ) File Line ( channel #1 ) Measure frame ( x 31, y 61, Width 1330,Height 978 ) Image frame ( x 0, y 0, Width 1392, Height 1040 )  --Calvalue = 0.0083 mm/pixel CALVALUE = 0.0083 Calibrate ( CALVALUECALUNITS$ per pixel ) For ( REPLICATE = 1 to FIELDS, step 1 )  ClearFeature Histogram #1  Clear Feature Histogram #2  Clear Accepts  IMAGEACQUISITION AND DETECTION  PauseText ( “Position sample, focus image andset white level to 0.95.” )  Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00,  ExposureTime 200.00 msec, Brightness 0,Lamp 49.99 )  Acquire ( into Image0 ) ACQOUTPUT = 0  -- The followingline can be optionally set-up for saving image files to a specific location. ACQFILE$ = “C:\Images\39291 - for Height\Text. 2H_“+STR$(REPLICATE)+”s.jpg” Write image ( from ACQOUTPUT into fileACQFILE$ ) Detect ( whiter than 104, from Image0 into Binary0 delineated) IMAGE PROCESSING Binary Amend (Close from Binary0 to Binary1, cycles4, operator Disc, edge erode on) Binary Amend (Open from Binary1 toBinary2, cycles 4, operator Disc, edge erode on) Binary Identify(FillHoles from Binary2 to Binary3) Binary Amend (Close from Binary3 toBinary4, cycles 15, operator Disc, edge erode on) Binary Amend (Openfrom Binary4 to Binary5, cycles 20, operator Disc, edge erode on)PauseText ( “Fill in projection & land regions that should be included,and reject over detected regions.” ) Binary Edit [PAUSE] ( Draw fromBinary5 to Binary6, nib Fill, width 2 ) PauseText ( “Select ‘Land’region for measurement.” ) Binary Edit [PAUSE] (Accept from Binary6 toBinary7, nib Fill, width 2 ) PauseText ( “Select ‘Projection’ region formeasurement.” ) Binary Edit [PAUSE] ( Accept from Binary6 to Binary8,nib Fill, width 2 ) -- Combine land and projection regions withmeasurement grid. Graphics ( Grid, 30 x 0 Lines, Grid Size 1334 × 964,Origin 21 × 21, Thickness 2, Orientation 0.000000, to Binary15 Cleared )Binary Logical (C = A AND B : C Binary10, A Binary7, B Binary15) BinaryLogical (C = A AND B : C Binary11, A Binary8, B Binary15) MEASUREHEIGHTS -- Land region only Measure feature (plane Binary10, 8 ferets,minimum area: 8, grey image: Image0 )  Selected parameters: X FCP, YFCP, Feret90 Feature Histogram #1 ( Y Param Number, X Param Feret90,from 0.0100 to 5.,  logarithmic, 20 bins ) Display Feature HistogramResults ( #1, horizontal, differential, bins + graph (Y axis linear),statistics ) Data Window ( 1278, 412, 323, 371 ) -- Projection regionsonly (includes any underlying land material) Measure feature ( planeBinary11,8 ferets, minimum area: 8, grey image: Image0 )  Selectedparameters: X FCP, Y FCP, Feret90 Feature Histogram #2 ( Y Param Number,X Param Feret90, from 0.0100 to 10.,  logarithmic, 20 bins ) DisplayFeature Histogram Results ( #2, horizontal, differential, bins + graph(Y axis  linear), statistics ) Data Window ( 1305, 801, 297, 371 )OUTPUT DATA File ( “Land Height (mm)”, channel #1 ) File Line ( channel#1 ) File Feature Histogram Results ( #1, differential, statistics, bindetails, channel #1 ) File Line ( channel #1 ) File Line ( channel #1 )File ( “Projection + Land Height (mm)”, channel #1 ) File Line ( channel#1 ) File Feature Histogram Results ( #2, differential, statistics, bindetails, channel #1 ) File Line ( channel #1 ) File Line ( channel #1 )File Line ( channel #1 )  Next ( REPLICATE )  Close File (channel #1)END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter sample identificationinformation which is sent to a designated EXCEL file to which themeasurement data will also be subsequently sent.

The analyst is then prompted to position the mounted samplecross-section on the auto-stage 336 possessing the darkened backgroundso the cross-sectional face is flush to the camera 330 with projectionsdirected upward and the length running horizontally in the live imagedisplayed on the video monitor screen. The analyst next adjusts thevideo camera 330 and lens' 340 vertical position to optimize the focusof the cross-sectional face. The illumination level is also adjusted bythe analyst via the Variable Auto-transformer to a white level readingof approximately 0.95.

Once the analyst completes the above steps and executes the continuecommand, an image will be acquired, detected and processed automaticallyby the QUIPS algorithm. The analyst will then be prompted to fill-in thedetected binary image, using the computer mouse, of any projectionand/or land areas shown in the cross-sectional image that should havebeen included by the previous detection and image processing steps aswell as rejecting any over detected regions that go beyond theboundaries of the cross-sectional structure shown in the underlyinggray-scale image. To aid in this editing process, the analyst can togglethe ‘control’ and ‘B’ keys on the keyboard simultaneously to turn theoverlying binary image on and off to assess how closely the binarymatches with the boundaries of the sample shown in the cross-section. Ifthe initial cross-sectioning sample preparation was performed well,little if any manual editing should be required.

The analyst is now prompted to “Select ‘Land’ region for measurement”using the computer mouse. This selection is performed by carefullydrawing a vertical line down through one side of a single land arealocated between or adjacent to projections and then, with the left mousebutton still depressed, moving the cursor beneath the land area to itsopposite side and then drawing another vertical line upward. Once thishas occurred, the left mouse button can be released and the land area tobe measured should be filled in with a green coloring. If the verticaledges of the resulting selected region are skewed in any way, theanalyst can reset to the original detected binary by clicking on the‘Undo’ button located within the Binary Edit window and begin theselection process again until straight vertical edges on both sides ofthe selected land region are obtained.

Similarly, the analyst will next be prompted to “Select ‘Projection’region for measurement.” The top portion of a projection region adjacentto the previously selected land area is now selected in the same mannerthat was previously described for a land area selection.

The algorithm will then automatically perform measurements on bothselected regions and output the data, in histogram format, into thedesignated EXCEL spreadsheet file. In the EXCEL file, the histograms forland and projection regions will be labeled “Land Height (mm)” and“Projection+Land Height (mm),” respectively. A separate set ofhistograms will be generated for each selection of land and projectionregion pairs.

The analyst will then again be prompted to position the sample and beginthe process of selecting different land and projection regions. At thispoint, the analyst can either use the auto-stage joystick to move thesame cross-section to a new sub-sampling position or an entirelydifferent mounted cross-section obtained from the same sample can bepositioned on the auto-stage 306 for measurement. The process forpositioning the sample and selecting land and projection regions formeasurement will occur six times for each execution of the QUIPSalgorithm.

A single projection height value is then determined by calculating thenumerical difference between the mean values of the separate land andprojection region histograms for each single pair of measurements. TheQUIPS algorithm will provide six replicate measurement sets of both landand projection regions for a single sample so that six projection heightvalues will be generated per sample. The final sample mean spread valueis usually based on an N=6 analysis from six, separate subsamplemeasurements. A comparison between different samples can be performedusing a Student's T analysis at the 90% confidence level.

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to 3;3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any documents is notto be construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by reference, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

When introducing elements of the present disclosure or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Many modifications and variations of the present disclosurecan be made without departing from the spirit and scope thereof.Therefore, the exemplary embodiments described above should not be usedto limit the scope of the invention.

What is claimed is:
 1. An absorbent article comprising: a) alongitudinal direction and a transverse direction; b) a longitudinalcenterline and a transverse centerline; c) an anterior region, aposterior region, and a central region positioned between the anteriorregion and the posterior region; d) an anterior region transversedirection end edge, a posterior region transverse direction end edge,and a pair of longitudinal direction side edges extending between andconnecting the anterior region transverse direction end edge and aposterior region transverse direction end edge; e) a topsheet layerdefining a body facing surface of the absorbent article, a liquidimpermeable layer defining a garment facing surface of the absorbentarticle, and an absorbent core positioned between the topsheet layer andthe liquid impermeable layer; and f) an exudate management layer influid communication with the topsheet layer, the exudate managementlayer comprising a first component comprising an outer peripheral edgeand an opening in the exudate management layer, the opening locatedinward from the outer peripheral edge and having a perimeter partiallydefined by an inner edge of the first component; and a second componentconnected to the first component via a primary fold, the primary folddefining a remaining perimeter of the opening, and the second componentextending from the primary fold such that a portion overlaps orunderlaps with the first component and a remaining portion extends pastthe outer peripheral edge.
 2. The absorbent article of claim 1 whereinthe exudate management layer is positioned on the body facing surface ofthe topsheet layer.
 3. The absorbent article of claim 1 wherein theexudate management layer is positioned between the topsheet layer andthe absorbent core.
 4. The absorbent article of claim 1 furthercomprising an acquisition layer positioned between the topsheet layerand the absorbent core.
 5. The absorbent article of claim 1 wherein theopening is positioned between the transverse centerline and theposterior region transverse direction end edge.
 6. The absorbent articleof claim 1 wherein the secondary component extends from the primary foldin the longitudinal direction towards the posterior region of theabsorbent article.
 7. The absorbent article of claim 1 wherein thesecond component comprises a secondary fold on the remaining portionpast the outer peripheral edge.
 8. The absorbent article of claim 1wherein the secondary component is divided into a first secondarycomponent and a second secondary component such that the primary foldcomprises a first primary fold and a second primary fold on opposingportions of the remaining perimeter, the first secondary componentextending from the first primary fold such that the portion overlaps orunderlaps with the first component and the remaining portion extendspast the outer peripheral edge and the second secondary componentextending from the second primary fold such that the portion overlaps orunderlaps with the first component and the remaining portion extendspast the outer peripheral edge in an opposing direction.
 9. Theabsorbent article of claim 8 wherein the first secondary componentextends from the first primary fold in the longitudinal direction towardthe posterior region of the absorbent article and the second secondarycomponent extends from the second primary fold in the longitudinaldirection towards the anterior region of the absorbent article.
 10. Theabsorbent article of claim 1 wherein the absorbent article furthercomprises an opposing pair of containment flaps extending in thelongitudinal direction of the absorbent article.
 11. The absorbentarticle of claim 1 wherein the topsheet layer is a fluid entangledlaminate web comprising a support layer comprising a plurality of fibersand opposed first and second surfaces; a projection layer comprising aplurality of fibers and opposed inner and outer surfaces, the secondsurface of the support layer in contact with the inner surface of theprojection layer, fibers of at least one of the support layer and theprojection layer being fluid-entangled fibers of the other of thesupport layer and the projection layer; a plurality of hollowprojections formed form a first plurality of the plurality of fibers inthe projection layer, the plurality of hollow projections extending fromthe outer surface of the projection layer in a direction away from thesupport layer; and a land area, wherein the plurality of hollowprojections are surrounded by the land area.
 12. The absorbent articleof claim 1 wherein the absorbent core comprises a body facing surfaceand projections extending away from the body facing surface of theabsorbent core.
 13. The absorbent article of claim 1 wherein the secondcomponent comprises at least one opening.